May/June 2001 Gear Technology
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Transcript of May/June 2001 Gear Technology
liNCD-ROM BUtSEE IP 141~
Revolultionary EllectlronicGuide System ellmlnatescostllY meehanleal chlangeover~Small-lot helical gear production winnever be the same not for users of theGleason Pfauter GP 300 IESGearShapero Imagine adding hundreds ofhours a year in valuablechip-making time to youroperation simply by
eliminating the time and effortyou now require for changingmechanical or hydrostatic guidefor every new workpiece lead
The GP 300 ES does this andmore In addition to its normalCNC axes the GP 300 ES uses a cutterhead with a backlash-free direct drive for
controlling the cutter spindle rotation(Esaxis) through a torque motor andsoftware Almost any helix anglewithin a wide range of stroking ratesand face widths can be createdsimply by changing the CNCprogram
E-Axls and softwaJfI forcontrolling cuttefspindle
rotation enable the GP 300 ESto produce helicaJgears
without a mechanical guae
End resultYou can handle newworkpiece leads -and shorten leadtimes -like never before
For more inpoundormationcontact
Tlhe Gleason WOlrksWOOUniversity Ave PO Box 22970
Rochester NY 14692-2970 USAPhone 716473~WOO Fax 716461~4348
Web site wwwgleasoncomE~Mail salesgleasoncom
Ct8Cl f10
bull t bull bull
MAYJUNE 2001
FEATURES
The Journal of Gear Manufacturing
FOCUS ON GEAR DESIGN
211
DEPARTMENTS
11
56
Talking On Nature Three IGearCompanies And Their End-ProductsA look at several gear manufacturers with special products on the side 18
IGearbox ~ieldl Pedormance from a IRebuUders PerspectivelTips on gearbox design from someone whos seen gearbox failures 22
Gealr Design Speciall Section 27
Design Formulas for Evaluating Contact Stress in Generalized IGearPairsDetermining contact stress no matter the gear type 3
alA CalcullatingllDynamic Loads Sizingl Worm Gearsand figuringl Geometry factorsTechnical editor Robert Errichello answers your design-related questions 39
load IDistribution lin IPIanetaryGearsPredicting the dynamic behavior of planetary gear systems 41
Publishers PageFinding your core competency 7
IRevolutionsA new planetary gear system and microgears 11
Industry NewsWhats happening in the gear industry 15
Adveniser IindexGet information from advertisers by using the response card or going online l1
Technical CalendarDont mi s these important upcoming events 46
CD~ROMBuyers Guiide FormsFREE USTlNGS for gear-industry companies 41
Product NewsThe latest products for gear design manufacturing and testing 150
literalllre MartFree brochures and catalogs from our advertisers 52
IClassifiedsServices Help Wanted and more 54
AddendumGear Fashion 56
VOL 18 NO3I GEAR TECHNOLOGV Tn Jourtllll or GolOr
Manu[aclurlllg (lSSN 01-13-6858) pubUhed bunonth-Iy by RaJdnJI Publishing Inc bull 1421 I~u Avenue POBox 1426 Elk Greve Village IL 600071amp471437-6604Cove price S~OO US rioltlJoaI postage paid alArlington HeIghtamp ILbull and 31 eddmonnl mailing offieeRandall Publishing makes eety ffort 10 ensure lhallhltprocesses descnbed in GEAR TECHNOLOltiY conformto soond engmecringpraaioe Neilher the authors IlOI thepublisher can be hed responsible for IJIjuri~s sustainedtill foil tho procedllrtS desenbed PostmasterSend address change to GEAR TECHNOLOGY Jcurnal of Gear Manufacturing 142~ Lum Avonue POBo 1426 Elk Grov ViUogelL 60007 OConlents copy-righted hy RANDALL PUB[JSHlNG TNC 2001 Nopart of this publication may be reproduced or uansmluedin any r or by any means olccllDic or 1llOclJanioaIincfudmg pOOllymg ncordioB or by any informationstorage and relrieval system withOUJEpermission in wrtt-Log ampom be publisber Cootents 0( ads IOIljecl 10
CIRC(E136 LPo_b_lilhr_middot_ _pprDi__Ill JI
4 MAYJUNE 2001 bull GEAR TECHNOLOGY bull ww~98rt9chngycom wwwpowertransmlssloncom
OLS
EDITORIALPublisher amp Editor-in-CDief
Michael Goldstein
Managjng Editor WilIiam R Stott
Associate Editor Joseph L Hazelton
Editorial Consultant Paul R Goldstein
TeChnical EditorsRobert Errichello
Don McVittieRobert E Smith
Dan Thurman
ARTArt Dirtttor Jean Bartz
ADVERTISINGAdvertising Manager Patricia Flam
Advertising Coordinator Susan Brandl
CIRCULATIONICirculation Coordinator Dina Krauss
INTERNETInternet Editor Dan Mackenzie
Gear industry Home PagelMSalesPatricia Flam
powerrransmissUJ1MomTill SalesRobert Poll
RANDALL PUBLISHING STAFFPmident Michael Goldstein
Vice Presldent Richard GoldsteinAccounting Mary Lou Napadow
Phone 847-437-6604E-mailpeoplegeartechnologycom
Web wwwgeartechnologycomwwwpowertransmi~sioncom
BIPA_11OML
W
INACHi
G10 ba I Experti seFor All Applications
NACHI MACHINING T-eCHINOlOGY co17500 Twenty-Three Mi Ie Road Macomb Michigan 48044-1 103Phone (810)-263-0100 Fax (810)-263-4571 WIMnachimtccom
NACHI MACHINING TECHNOLOGY CO
Combining over 140 years I)f processmachine and tool experience enables NachiliMachining Technology Co to maintainiindustry leadership by proviiding customerswith the best practices manufatctuningsolutions
For the finest products penormence serviceand global support you can rely on NachiMTCto meet your application need today andtomorrow
Broach nd GearFinishing ProductsBroacJlIna
VerticalHOrizontalPolSurfaceBlind SplineVel1caJ Wo Transs
Geal 500vingRoll FormingRoll FinishingHobblngTool SharpeningHoningGeBlnspectionForm Gnndlng
CIRc~n4
_-----------IIPUBUSHERS IPAGiE 1 _
Co CoConcentrating on the CllAdal Components
Co Keep Yow CompanyCompe+i+ive
Rodgers and Hammerstein producedorne of Americas most memorable and
lasting songs in musical theater lyricistOscar Hammerstein IIonce aid of com-poser Richard Rodgers I hand him alyric and get out of his way Hammer-stein knew what Rodgers was good atand vice versa and each trusted his part-ner Their partnership was 0 successfulthat you can scarcely think of one manwithout the other
Musical composers arent the onlyones who form uccessful partnership mntodays manufacturing world partner-ships arealmo t a necessity Originalequipment manefacturers have competi-Lion not only from other manufacturersof similarequipment but 3110 from man-ufacturers of the components that go intotheitrequipment and the service pro-viders who process some of those com-ponems along the way
Ron Davi of Caterpillar Tnc madethis point at the recent annual meetingof the American Gear ManufacturersAs ociation Davis works in Caterpil-lars busine s administration divisionwhich help decide when to manufac-ture components in-house and when tooutsource them
Caterpmarequipment require abroad range of gear products includingtransmission shafts straight and spiralbevel gears planet gears sun gears andfinal drive ring gears They use largequantities of both machined and powdermetal gears
But Caterpillar cant hope to staycompetitive by rnanufaciuri ng all of itscomponents when other companies spe-cialize in manufacturing some of thosecomponents Davis says
The challenge is to decide whichcomponents and manufacturing process-es give Caterpillar the greatest competi-tive advantage when manufactured in-house and which give them the greatestcompetitive advantage when outsourcedOf course the ccmpanyexamines factorssuch as cost quality and customer satis-faction when considering competitiveadvantage Another factor is whetherCaterpillar has special expertise in man-ufacturing a particular component Thecompany also examines various risk cri-teria whether a part requires proprietarytechnology whether its an aftermarket-critical component or whether its time-to-market is critical
Those components that give them thegreatest competitive advantage whenmanufactured in-house are part of Cat-erpillars core competency Outsourcingthose components could lower the quali-Iy of the end-product make it moreexpensive or otherwise worsen the com-panys position in the marketplaceComponent that are not a part ofCaterpillars core competency might bebetter manufactured by others special-ists who can lower the costs improve thequality or both Outsourcing those nOI1-
core components also affords Caterpillarthe opportunity to devote its ownresources to improving those processesand products that are part of its covecompetency
Many of Caterpillars less criticalhigh-volume components such as enginegears are generally outsourced Criticalcomponents such as large transmissionsor filial drive gears are generally manu-factured in-house Medium-duty compo-nents such as small axles and small
transmissions are mixed between in-house manufacturing and outsourcing
Some of the ontsoureed gears aremanufactured by Avon Gear Co a divi-sion of Okubo Gear Co Ltd inRochester Hill MI At the AGMA meet-ing ] had the chance to talk with AvonGears president Aaron Remsing
According to Rem ing there was alime not long ago when Avon Gear hada near-death experience Business wasdown the company had just moved intoa new expensive building and thefuture wa uncertain Avon Gear had todo some soul-searching about its busi-ness Management wa forced to thinkabout the companys capabilities andreinvent the way that it obtained newbusiness Rernsing says The answer layin examining the companys own corecompetencies
Avon Gear knew it had the technicalexpertise equipment and experience tomanufacture certain sizes Iypes andquantities of gears of excellcru qualityand at competitive prices Instead ofwaiting for orders to come in Remsing
wlO powertransmuoncom bull f1OfgllarrechnoJogycom bull GEAR TECHNOLOGY 11IYfJUNE 2001 7
PUBLISHERS PAGEsays the company began approachingthose customers who could best takeadvantage of Avon Gears core compe-tencies One of those companies wasCaterpillar
By making a commitment to special-ize in a certain type of gear for a certainmarket segment Avon Gear was able tocapture Caterpillars business That busi-ness in tum allowed the company anopportunity to invest in new equipment
and training to provide even greater com-petitive advantage
Today according to Davis AvonGear is one of the most important sup-pliers for Caterpillars transmissionbusiness unit Working together thecompanies are able to provide theworld-class manufacturing quality andpricing on gear components that helpkeep Caterpillars equipment competi-tive in the world market Furiliermore
bullIng
Remove nicks buns hest treat scaleand Improve gear tooth surface
Onr 30 J8IlI ago morllaar1lalll developed the gelDbilihlmidlddDglllllllilnnJllOC8llPat JOU trust In tbe people who Invented the process
MAatlNE FEATURESINCLUDEbull Fully automated systemsbull High speed machinesbull Patented Gerac
Oscillation Systembull Automatic spherical
position Ingbull Trl-varlable die designbull Horizontal or vertical axis
machinesbull Variety of gear types
For additional information on IhHuBurnishingandor Functional flfiu
Inectionvisit our website ottIVIIVw ilWgearscom
ITP1tl HeartlandWorkilll9 components 01 theHorizontal Bumisher
1205 36th Avenue WestAlexandria MN 56308 USA
Ph (320) 762-8782Fax (320) 782-5280
E-mail ItwgeaISOrea-alpoom
8 MAYJU NE 2001 GEAFi TECHNOLOGYmiddot www9Ilartllchnolo9ycom bull wWWpowllrtransmissioncom
~c~l(JoldsteinPublisher amp Editor-in-Chief
the processes machines and expertisedeveloped by Avon Gear have given thecompany the ability to sell gears ofworld-class quality and price to othercustomers with similar needs
In fact Davis saysthe partnershipbetween these two companies has devel-oped into one of mutua] trust and plan-ning Like most successful partnershipsits now in the best interest of each partythat the other doesnt fail
Like Caterpillar and Avon Gear eachof our own companies has core compe-tencies-things that are central to ourbusiness which years of working in cer-tain areas allow us to do better than othercompanies without the same focusFinding those things concentrating onthem and expanding on them can helpmake us more successful
Not finding and developing your corecompetency can have the opposite effectIts true that some companies will bemore focused than others But even themost generalist of companies has corecompetencies For example a general-purpose gear job shop with a broad rangeof equipment and tooling might not seemto have a specific niche Neverthelessthat same company might specialize infast turnaround design assistance orextremely high quality each of whichcould be developed for greater competi-tive advantage in certain marketplaces
You can learn more about your corecompetencies by choice or by necessityIf you do so by choice perhaps you II beable to make intelligent decisions aboutyour companys operations as Caterpil-lar did However if you wait you may beforced to learn about your core compe-tencies the hard way Perhaps youll beable to act quickly enough to save yourcompany as Avon Gear did But thenagain
For 96 years the Bodine name has symbollized quality in power transmissionand motlon control IBodine EIectric Company pioneered the concept ot fracticnalhorsepower motors with integrall gear reducers We calrefully guard our reputationfor producing the quietest smoothest Iiongest-life products in the industry
Now you can tnccrporate those same higlhstandards of qualityrellabtlltyand on-time deillivelry iinto your products that require filneand medium pitch open gears from hundreds to hundreds oftLo - - - ~ -d -nousancs
Bodine Gear Manufacturing employs state-of-the-art eNG gearmanufactuning and inspection technology with in-depthengineening support to service your most demandinQappucattons For skived gears we can be your most competitiivecompetent source
To learn more about Bodiine Gear Manufacturing and get your Free Bodiine Gears capvisit ww-wBodineGearscomFreeCaphtm or call toll flree 877-4GEARS9
Sales Representative inquiries welcome
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Dura-Bars continuous-cast gray and ductileiron performs like free-machining steel with anImportantadded bonus - quieter operation
Like steel Dura-Bar can he austemperedthrough-hardened flame-hardened or induction-hardened for added wear resistance Butthesuperior noise and vibration damping characteristicsof Dura-Bar make for quieter runninggears AndDura-Bar is 10Ughter than steel
Dura-Bar round bars are avatlable In diametersnnging from 58~ to 20 and lengths of 6-20 So youwont need to make major changes in your machining equipment And our extensive mventory means Dura-Bar is available now - when you need U
Wben Its quaUtymaterial quiet performance and quick deUverythatcount look to continuous-cast Dura-Bar for your gear production needs
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REVOLUTIONS -- _
Hlarmonic ConceptsJazz lp
Planetary DesiglnIn the world of planetary
servo drives precision iseverything Advertisementsabound fOJ ervo gear driveswith extremely low or evenzere backlash With that typeof drive in high demand man-ufacturers have done every-thing they can to tighten theirdesigns-thmugh more exact-ing tolerances tighter assem-bly and better materials
Instead of tightening onemanufacturer of planetaryservo drives has tried loosen-
mg in order [0 provide the lowbacklash that manufacturers ofrobotics and other precise posi-
tioning equipment requireThat loosening bas nothing
te do with the manufacturingtolerances or assembly Pre-cision manufacturing is stillrequired Ithas to do with atype of flexibility borrowedfrom a related technologyharmonic drive gearing
Harmonic drive gearinghas long been known for itslow backlash high precisionand compact design Har-monic drive systems use a cir-cular spline a flex spline and
Cut-away view of the HPG gear drive from HIl Systems
me HPG drive includes II 11111 lIear 10 cantro bacldash(defoRnltion 8xallllerated for mustrative purposes
wavegenera~or to createextremely high ratios in a sin-gle reduction One of theadvantages of the harmonicdrive system is that the flexspline deforms as it rotates tokeep its teeth fully loadedagainst the circular spline alaU times
Engineers at HD Systems ofHauppauge NY haveliguredout how to apply the deforma-tion concept of harmonic drivesystems to planetary gears aswell Instead of a flexible imlerspline bull the HPG harmonicplanetary gearheads use aflexible outer ring gear to pre-load the gearset
The flexible outer ringgear of the HPG gearheadcreates a continually adju l-ing backlash compensationmethod The ring gear is thin-ner in the radial directionthan a typical ring gear Thismakes it radjaUy flexible yettorsionally stiff says HDSystems marketing managerBrian St Denis As normal
Wecome to Revolu-
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most up-to-dBtl ndeasY-Io-read informll-
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nd technology of thegell industry Revolu-
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Technologv PO Box1426 flk Grore VillageIt 60009 or fx (HI)
431-6618 If youd like
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gear wear occurs any in-crease in space between the
jteeth is immediately compen- Isated by the preload in the ring gear The concept is as if Ithe ring gear is a spring in the Iradial direction
The system employed byHD Systems has a huge advan-tage over those commonlyemployed by other maaufac-turers says St Denis Thebackla h of the HPG drivewont deteriorate over time
One method commonlyemployed toprovide low orzero backlash ill planetarygear systems is to create atight fit between all of thegears However this methodis subject to gear tooth wearand over the life of the gear-box the backl3sll can increasesignificantly
Another method is to usepreloaded bevel gears as panof the mechanism Shimsforce the bevel gears togetheraxially which forces a raclialpreload in the planetary gearsBacklash in this type of sys-tem also increases over timebecause of gear tooth wear
Because of the flexibledefermation of the planetaryring gear the HPG gearheadautomaucally compensatesfor gear tooth wear 81 Dellisays This helps ensure con-sistent backlash throughoutthe rated life of the gearbox
The H~ Series planetarygearheads have standardbacklash of less than 3 arc-minutes and they can beordered with 1 arc-minute ofbacklash as an option Theyare available in ratios from51 to 331
Cirele3mwwwpow9rrsnsmlssloncom bull wwwge8rtechnQJoycom bull GEAR TECHNOLOGYmiddotmiddot MAYJUNE 2001
MicmgearsFor Use In Tlhe
IHuman MachineIn a Hungarian lab using a
microscopes laser research-ers are creating gears androtors thinner than a humanhair ADd willie hair growsout of the body the re-searchers want to put theirgears and rotors into the bodyin microsoopic machines forconducting experiments
Its like the movie innerSpace wilh Dennis Quaidsays researcher p~ OrmosThe machines could be builtso small that they would fitinto blood vessels for analyz-ing blood
To create the gears androtors Onnos uses hardenedliquid photopolymer Butunlike the micropans and their
pos ible lise the material isntnearly as exotic
Dentists use it a letann os says The material isthe same as whats II ed fortooth fillings hardened withultraviolet light
Ormes developed the tech-nique with Fewr Galajda in alittle more than a year--Just now weare perfectingit Ormes acids that hed likero use the technique in lessthan a year to build everaltypes of machine
Willi a doctorate ill phys-ics Ormos belongs to theHungarian Academy of Sci-ences and works at itsBiological Research Centrelocated in Szeged Ormos isdirector of the centres Insti-tnte of Biophy it Galajda istis doctoral snrdent
We study thephysics of
Created undBr II microscope threll rotan appear in front of the Dak-likeIJIIJ1Jc lif bullbullbull II 110mB n bairLivingsystems Ormes says Ormos and Galajdas gearsHe acids lliat theres a strong and rotors could be usedjndrive ill biology toward minia- that study as parts in micro-turizing which has a lot of scopic biochemical device promise in it The micromachines would be
bull accuracybull reliabilitybull maintolinCibilitybull Hexibilily performancebull and life cyde eest
AI Klingelnberg the point ofprecision is 10 help you controlyour gear manufocturing pro-cess and improve gearqudlitywith measuring systems thaIare benchmarks for
Klingelnberg measuringtechnology contaeLiebherr Gear Technology Co1465 Woodland DriveSaline MI4B 176-1259
_------------REVOLUTIONS------------_used ro investigate living sys-terns at a cellular level per-mitting the movement of indi-vidual ceIls-even individuallarge molecules Ormos says~ts a very precise tool thatcan be used in biology
With such machines scien-tists could introduce chemi-cals into cells manipulatetheir reactions and maintainthose cells environmentspumping different solutions todifferent regions They couldmeasure cell properties toselect certaia cells create achannel for transporting thosecells and transport the cellsindividually They could alsoremove compounds fromcells even destroy cells
The gears and rotors diam-eters can be as small as twomicrons A human hales diam-eter is about 100 microns At
two microns the parts canweigh as little as ]()LO grams
Ormos and GaIajda maketheir microparts by placingliquid photopolymer under amicroscope then moving acomputer-controlled laser fo-cus into the microscopeWhereverthe focus movesthe liquid becomes hardenedIf it moves in a gear shape thefocus makes a hardened gear
We can create a three-dimensionalobject that is ascomplicated as we wantOrmes says
DUI theres a wri nkle inthe technology that needs tobe ironed out
The micro gears are rotatedby the microrotors The micro-rotors are rotated by light
Its not easy to introducelight into the blood vesselsOmms says
But he adds there may be asolution to that problemOrmos explains that themachines in the body could bepowered by tightlfit wereintroduced effectively-via athin optic fiber for example
In similar research SandiaNational Laboratories in NewMexico has used chemicalmiddotelching to create microgearsand experimental micro-engines electric motors no
1 larger than a grain of sandOrmos started his research
j to understand how light causesI different trapped particles toj rotate But he later realizedi such light-induced rotationi could have useful applicationsI
1 It was not really the areaI
1 in which we were deliberately
II
moving he saysOnnos is unsure about the
techniques future-Whether
this can be commercialized ornot isnt clear Still he andOalajda are testing resins todecide which works best forcreating their gears and rotors
I think the possibilities arereally uolimited Ormes saysAnything that can be donewith larger machines can bedone with smaller ones too
Cirde302
Tbullbull V
If you found tIriI IfticfI ofinterest andor UIefuI
~
l1~~
Phone + 1-734-429-7225Fax 1-734-429-2294wwwpointofprecisioncominfopointofprecisioncom
bull 1INDUSTRV NEWS _
Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
S86 HilliardStreet RO Box 1898 Manchester CT06045-1898 USATelephone 86() 1649-0000 bull Fax 860 645-629g
Home Page httpwwwpurdytransmissionscomf-Mail salespurrlytransmissonsfOffl
Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
Fifty years or VARI-ROLL applications providebull Production Composite Inspectionbull Custom Design amp Build Part Gear Mounting Fixturesbull Standard Mounting Fixtures - Spurs Helicals Pinion Shafts
Worms Throated Worms Bevels Internals
When coupled with the VARI-PC Composite Gear AnalysisSystem will providebull Reduced Inspection Cost Improved Accuracy Historical Record Keepingbull Serialization of Partsbull Interface to SPC programsExperience the difference See why customers worldwide havechosen the VARI-ROLUVARImiddotPC For further informationplease contact us
Precision Gage ce Inc100 Shore Drive Burr Ridge IL 60521
630-655-2121 Fax630-6S5-3073wwwpredsiongagecocom
United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
CIRCLE 1Ji
ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
Will YoI TIIiIk bullbullIf you found 1his column of inbaIt lIIdIoruseful pIe
If did notcn forflll coIumn _
I
If you would like to mpond to this or anyother article In tltil adlllon of 60rTMhntw=faxvour ~totheIIlIfIdon If SIDU manqlnt edIIur ItIMJ437-1818 or I8ftd melII1D ~com
16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
S- Amcricllinc
Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
far __ illfonnalion eIIouI bull prIIIiucI DIIHrYiCJ JdHftIMd Ii hil iUIIII IIf 6_rfthohlfr I~-IM appropriate IIIUIIIber IIIIM lIIdr IInpg_ Callli MIlput ilia clrd in Ihe lIIIiI
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IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
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Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
1_1 I)CiuIG~tIJ TlaquohnoIDV
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ORPORATION
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TooHnk Engineeringoffers hydraulic arbors
made of a lightmetal alloy that
weigh up to70 less thana comparable
steel arborFeather lighthydraulicarbors can bemanufactured wilhrunout as low as2 microns The clampingsleeves are replaceabte Thistoolingl is suitable for measuringtesting balancinggear grindingand other applications
T_~O _--UIoIt--~-- ~~-~-~_ _ -1IIrIndIrit bull T-g bull LDbull OD ~-IumIn~
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An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
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If you would like more information about Pialllurgh ccirc ~If you would like to respond to this or any other articlein this edition of Gear Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-661 B
WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
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IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
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For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
If you found this article of interest andoruseful pI sa circle
MAYJUNE 2001 bull GiEAR TECHNQlQGY wWlIgurechlloloQycom bull wwwpowerlrslIsmluloncom
GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
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powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
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Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
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bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
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PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
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MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
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Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
Revolultionary EllectlronicGuide System ellmlnatescostllY meehanleal chlangeover~Small-lot helical gear production winnever be the same not for users of theGleason Pfauter GP 300 IESGearShapero Imagine adding hundreds ofhours a year in valuablechip-making time to youroperation simply by
eliminating the time and effortyou now require for changingmechanical or hydrostatic guidefor every new workpiece lead
The GP 300 ES does this andmore In addition to its normalCNC axes the GP 300 ES uses a cutterhead with a backlash-free direct drive for
controlling the cutter spindle rotation(Esaxis) through a torque motor andsoftware Almost any helix anglewithin a wide range of stroking ratesand face widths can be createdsimply by changing the CNCprogram
E-Axls and softwaJfI forcontrolling cuttefspindle
rotation enable the GP 300 ESto produce helicaJgears
without a mechanical guae
End resultYou can handle newworkpiece leads -and shorten leadtimes -like never before
For more inpoundormationcontact
Tlhe Gleason WOlrksWOOUniversity Ave PO Box 22970
Rochester NY 14692-2970 USAPhone 716473~WOO Fax 716461~4348
Web site wwwgleasoncomE~Mail salesgleasoncom
Ct8Cl f10
bull t bull bull
MAYJUNE 2001
FEATURES
The Journal of Gear Manufacturing
FOCUS ON GEAR DESIGN
211
DEPARTMENTS
11
56
Talking On Nature Three IGearCompanies And Their End-ProductsA look at several gear manufacturers with special products on the side 18
IGearbox ~ieldl Pedormance from a IRebuUders PerspectivelTips on gearbox design from someone whos seen gearbox failures 22
Gealr Design Speciall Section 27
Design Formulas for Evaluating Contact Stress in Generalized IGearPairsDetermining contact stress no matter the gear type 3
alA CalcullatingllDynamic Loads Sizingl Worm Gearsand figuringl Geometry factorsTechnical editor Robert Errichello answers your design-related questions 39
load IDistribution lin IPIanetaryGearsPredicting the dynamic behavior of planetary gear systems 41
Publishers PageFinding your core competency 7
IRevolutionsA new planetary gear system and microgears 11
Industry NewsWhats happening in the gear industry 15
Adveniser IindexGet information from advertisers by using the response card or going online l1
Technical CalendarDont mi s these important upcoming events 46
CD~ROMBuyers Guiide FormsFREE USTlNGS for gear-industry companies 41
Product NewsThe latest products for gear design manufacturing and testing 150
literalllre MartFree brochures and catalogs from our advertisers 52
IClassifiedsServices Help Wanted and more 54
AddendumGear Fashion 56
VOL 18 NO3I GEAR TECHNOLOGV Tn Jourtllll or GolOr
Manu[aclurlllg (lSSN 01-13-6858) pubUhed bunonth-Iy by RaJdnJI Publishing Inc bull 1421 I~u Avenue POBox 1426 Elk Greve Village IL 600071amp471437-6604Cove price S~OO US rioltlJoaI postage paid alArlington HeIghtamp ILbull and 31 eddmonnl mailing offieeRandall Publishing makes eety ffort 10 ensure lhallhltprocesses descnbed in GEAR TECHNOLOltiY conformto soond engmecringpraaioe Neilher the authors IlOI thepublisher can be hed responsible for IJIjuri~s sustainedtill foil tho procedllrtS desenbed PostmasterSend address change to GEAR TECHNOLOGY Jcurnal of Gear Manufacturing 142~ Lum Avonue POBo 1426 Elk Grov ViUogelL 60007 OConlents copy-righted hy RANDALL PUB[JSHlNG TNC 2001 Nopart of this publication may be reproduced or uansmluedin any r or by any means olccllDic or 1llOclJanioaIincfudmg pOOllymg ncordioB or by any informationstorage and relrieval system withOUJEpermission in wrtt-Log ampom be publisber Cootents 0( ads IOIljecl 10
CIRC(E136 LPo_b_lilhr_middot_ _pprDi__Ill JI
4 MAYJUNE 2001 bull GEAR TECHNOLOGY bull ww~98rt9chngycom wwwpowertransmlssloncom
OLS
EDITORIALPublisher amp Editor-in-CDief
Michael Goldstein
Managjng Editor WilIiam R Stott
Associate Editor Joseph L Hazelton
Editorial Consultant Paul R Goldstein
TeChnical EditorsRobert Errichello
Don McVittieRobert E Smith
Dan Thurman
ARTArt Dirtttor Jean Bartz
ADVERTISINGAdvertising Manager Patricia Flam
Advertising Coordinator Susan Brandl
CIRCULATIONICirculation Coordinator Dina Krauss
INTERNETInternet Editor Dan Mackenzie
Gear industry Home PagelMSalesPatricia Flam
powerrransmissUJ1MomTill SalesRobert Poll
RANDALL PUBLISHING STAFFPmident Michael Goldstein
Vice Presldent Richard GoldsteinAccounting Mary Lou Napadow
Phone 847-437-6604E-mailpeoplegeartechnologycom
Web wwwgeartechnologycomwwwpowertransmi~sioncom
BIPA_11OML
W
INACHi
G10 ba I Experti seFor All Applications
NACHI MACHINING T-eCHINOlOGY co17500 Twenty-Three Mi Ie Road Macomb Michigan 48044-1 103Phone (810)-263-0100 Fax (810)-263-4571 WIMnachimtccom
NACHI MACHINING TECHNOLOGY CO
Combining over 140 years I)f processmachine and tool experience enables NachiliMachining Technology Co to maintainiindustry leadership by proviiding customerswith the best practices manufatctuningsolutions
For the finest products penormence serviceand global support you can rely on NachiMTCto meet your application need today andtomorrow
Broach nd GearFinishing ProductsBroacJlIna
VerticalHOrizontalPolSurfaceBlind SplineVel1caJ Wo Transs
Geal 500vingRoll FormingRoll FinishingHobblngTool SharpeningHoningGeBlnspectionForm Gnndlng
CIRc~n4
_-----------IIPUBUSHERS IPAGiE 1 _
Co CoConcentrating on the CllAdal Components
Co Keep Yow CompanyCompe+i+ive
Rodgers and Hammerstein producedorne of Americas most memorable and
lasting songs in musical theater lyricistOscar Hammerstein IIonce aid of com-poser Richard Rodgers I hand him alyric and get out of his way Hammer-stein knew what Rodgers was good atand vice versa and each trusted his part-ner Their partnership was 0 successfulthat you can scarcely think of one manwithout the other
Musical composers arent the onlyones who form uccessful partnership mntodays manufacturing world partner-ships arealmo t a necessity Originalequipment manefacturers have competi-Lion not only from other manufacturersof similarequipment but 3110 from man-ufacturers of the components that go intotheitrequipment and the service pro-viders who process some of those com-ponems along the way
Ron Davi of Caterpillar Tnc madethis point at the recent annual meetingof the American Gear ManufacturersAs ociation Davis works in Caterpil-lars busine s administration divisionwhich help decide when to manufac-ture components in-house and when tooutsource them
Caterpmarequipment require abroad range of gear products includingtransmission shafts straight and spiralbevel gears planet gears sun gears andfinal drive ring gears They use largequantities of both machined and powdermetal gears
But Caterpillar cant hope to staycompetitive by rnanufaciuri ng all of itscomponents when other companies spe-cialize in manufacturing some of thosecomponents Davis says
The challenge is to decide whichcomponents and manufacturing process-es give Caterpillar the greatest competi-tive advantage when manufactured in-house and which give them the greatestcompetitive advantage when outsourcedOf course the ccmpanyexamines factorssuch as cost quality and customer satis-faction when considering competitiveadvantage Another factor is whetherCaterpillar has special expertise in man-ufacturing a particular component Thecompany also examines various risk cri-teria whether a part requires proprietarytechnology whether its an aftermarket-critical component or whether its time-to-market is critical
Those components that give them thegreatest competitive advantage whenmanufactured in-house are part of Cat-erpillars core competency Outsourcingthose components could lower the quali-Iy of the end-product make it moreexpensive or otherwise worsen the com-panys position in the marketplaceComponent that are not a part ofCaterpillars core competency might bebetter manufactured by others special-ists who can lower the costs improve thequality or both Outsourcing those nOI1-
core components also affords Caterpillarthe opportunity to devote its ownresources to improving those processesand products that are part of its covecompetency
Many of Caterpillars less criticalhigh-volume components such as enginegears are generally outsourced Criticalcomponents such as large transmissionsor filial drive gears are generally manu-factured in-house Medium-duty compo-nents such as small axles and small
transmissions are mixed between in-house manufacturing and outsourcing
Some of the ontsoureed gears aremanufactured by Avon Gear Co a divi-sion of Okubo Gear Co Ltd inRochester Hill MI At the AGMA meet-ing ] had the chance to talk with AvonGears president Aaron Remsing
According to Rem ing there was alime not long ago when Avon Gear hada near-death experience Business wasdown the company had just moved intoa new expensive building and thefuture wa uncertain Avon Gear had todo some soul-searching about its busi-ness Management wa forced to thinkabout the companys capabilities andreinvent the way that it obtained newbusiness Rernsing says The answer layin examining the companys own corecompetencies
Avon Gear knew it had the technicalexpertise equipment and experience tomanufacture certain sizes Iypes andquantities of gears of excellcru qualityand at competitive prices Instead ofwaiting for orders to come in Remsing
wlO powertransmuoncom bull f1OfgllarrechnoJogycom bull GEAR TECHNOLOGY 11IYfJUNE 2001 7
PUBLISHERS PAGEsays the company began approachingthose customers who could best takeadvantage of Avon Gears core compe-tencies One of those companies wasCaterpillar
By making a commitment to special-ize in a certain type of gear for a certainmarket segment Avon Gear was able tocapture Caterpillars business That busi-ness in tum allowed the company anopportunity to invest in new equipment
and training to provide even greater com-petitive advantage
Today according to Davis AvonGear is one of the most important sup-pliers for Caterpillars transmissionbusiness unit Working together thecompanies are able to provide theworld-class manufacturing quality andpricing on gear components that helpkeep Caterpillars equipment competi-tive in the world market Furiliermore
bullIng
Remove nicks buns hest treat scaleand Improve gear tooth surface
Onr 30 J8IlI ago morllaar1lalll developed the gelDbilihlmidlddDglllllllilnnJllOC8llPat JOU trust In tbe people who Invented the process
MAatlNE FEATURESINCLUDEbull Fully automated systemsbull High speed machinesbull Patented Gerac
Oscillation Systembull Automatic spherical
position Ingbull Trl-varlable die designbull Horizontal or vertical axis
machinesbull Variety of gear types
For additional information on IhHuBurnishingandor Functional flfiu
Inectionvisit our website ottIVIIVw ilWgearscom
ITP1tl HeartlandWorkilll9 components 01 theHorizontal Bumisher
1205 36th Avenue WestAlexandria MN 56308 USA
Ph (320) 762-8782Fax (320) 782-5280
E-mail ItwgeaISOrea-alpoom
8 MAYJU NE 2001 GEAFi TECHNOLOGYmiddot www9Ilartllchnolo9ycom bull wWWpowllrtransmissioncom
~c~l(JoldsteinPublisher amp Editor-in-Chief
the processes machines and expertisedeveloped by Avon Gear have given thecompany the ability to sell gears ofworld-class quality and price to othercustomers with similar needs
In fact Davis saysthe partnershipbetween these two companies has devel-oped into one of mutua] trust and plan-ning Like most successful partnershipsits now in the best interest of each partythat the other doesnt fail
Like Caterpillar and Avon Gear eachof our own companies has core compe-tencies-things that are central to ourbusiness which years of working in cer-tain areas allow us to do better than othercompanies without the same focusFinding those things concentrating onthem and expanding on them can helpmake us more successful
Not finding and developing your corecompetency can have the opposite effectIts true that some companies will bemore focused than others But even themost generalist of companies has corecompetencies For example a general-purpose gear job shop with a broad rangeof equipment and tooling might not seemto have a specific niche Neverthelessthat same company might specialize infast turnaround design assistance orextremely high quality each of whichcould be developed for greater competi-tive advantage in certain marketplaces
You can learn more about your corecompetencies by choice or by necessityIf you do so by choice perhaps you II beable to make intelligent decisions aboutyour companys operations as Caterpil-lar did However if you wait you may beforced to learn about your core compe-tencies the hard way Perhaps youll beable to act quickly enough to save yourcompany as Avon Gear did But thenagain
For 96 years the Bodine name has symbollized quality in power transmissionand motlon control IBodine EIectric Company pioneered the concept ot fracticnalhorsepower motors with integrall gear reducers We calrefully guard our reputationfor producing the quietest smoothest Iiongest-life products in the industry
Now you can tnccrporate those same higlhstandards of qualityrellabtlltyand on-time deillivelry iinto your products that require filneand medium pitch open gears from hundreds to hundreds oftLo - - - ~ -d -nousancs
Bodine Gear Manufacturing employs state-of-the-art eNG gearmanufactuning and inspection technology with in-depthengineening support to service your most demandinQappucattons For skived gears we can be your most competitiivecompetent source
To learn more about Bodiine Gear Manufacturing and get your Free Bodiine Gears capvisit ww-wBodineGearscomFreeCaphtm or call toll flree 877-4GEARS9
Sales Representative inquiries welcome
CIRetIE 109
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Theres only one way to ensure thatthe gears you produce win always deliversuperior and quiet performance Make suretheyre bred from quaUty stock
Dura-Bars continuous-cast gray and ductileiron performs like free-machining steel with anImportantadded bonus - quieter operation
Like steel Dura-Bar can he austemperedthrough-hardened flame-hardened or induction-hardened for added wear resistance Butthesuperior noise and vibration damping characteristicsof Dura-Bar make for quieter runninggears AndDura-Bar is 10Ughter than steel
Dura-Bar round bars are avatlable In diametersnnging from 58~ to 20 and lengths of 6-20 So youwont need to make major changes in your machining equipment And our extensive mventory means Dura-Bar is available now - when you need U
Wben Its quaUtymaterial quiet performance and quick deUverythatcount look to continuous-cast Dura-Bar for your gear production needs
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REVOLUTIONS -- _
Hlarmonic ConceptsJazz lp
Planetary DesiglnIn the world of planetary
servo drives precision iseverything Advertisementsabound fOJ ervo gear driveswith extremely low or evenzere backlash With that typeof drive in high demand man-ufacturers have done every-thing they can to tighten theirdesigns-thmugh more exact-ing tolerances tighter assem-bly and better materials
Instead of tightening onemanufacturer of planetaryservo drives has tried loosen-
mg in order [0 provide the lowbacklash that manufacturers ofrobotics and other precise posi-
tioning equipment requireThat loosening bas nothing
te do with the manufacturingtolerances or assembly Pre-cision manufacturing is stillrequired Ithas to do with atype of flexibility borrowedfrom a related technologyharmonic drive gearing
Harmonic drive gearinghas long been known for itslow backlash high precisionand compact design Har-monic drive systems use a cir-cular spline a flex spline and
Cut-away view of the HPG gear drive from HIl Systems
me HPG drive includes II 11111 lIear 10 cantro bacldash(defoRnltion 8xallllerated for mustrative purposes
wavegenera~or to createextremely high ratios in a sin-gle reduction One of theadvantages of the harmonicdrive system is that the flexspline deforms as it rotates tokeep its teeth fully loadedagainst the circular spline alaU times
Engineers at HD Systems ofHauppauge NY haveliguredout how to apply the deforma-tion concept of harmonic drivesystems to planetary gears aswell Instead of a flexible imlerspline bull the HPG harmonicplanetary gearheads use aflexible outer ring gear to pre-load the gearset
The flexible outer ringgear of the HPG gearheadcreates a continually adju l-ing backlash compensationmethod The ring gear is thin-ner in the radial directionthan a typical ring gear Thismakes it radjaUy flexible yettorsionally stiff says HDSystems marketing managerBrian St Denis As normal
Wecome to Revolu-
Iions th column tIItbrings you the Illtest
most up-to-dBtl ndeasY-Io-read informll-
tion bout the people
nd technology of thegell industry Revolu-
Uons welcomes OUsubmissions PleBSe
sefid them to Gear
Technologv PO Box1426 flk Grore VillageIt 60009 or fx (HI)
431-6618 If youd like
more infomllltion sbout
flY of the articles that
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gear wear occurs any in-crease in space between the
jteeth is immediately compen- Isated by the preload in the ring gear The concept is as if Ithe ring gear is a spring in the Iradial direction
The system employed byHD Systems has a huge advan-tage over those commonlyemployed by other maaufac-turers says St Denis Thebackla h of the HPG drivewont deteriorate over time
One method commonlyemployed toprovide low orzero backlash ill planetarygear systems is to create atight fit between all of thegears However this methodis subject to gear tooth wearand over the life of the gear-box the backl3sll can increasesignificantly
Another method is to usepreloaded bevel gears as panof the mechanism Shimsforce the bevel gears togetheraxially which forces a raclialpreload in the planetary gearsBacklash in this type of sys-tem also increases over timebecause of gear tooth wear
Because of the flexibledefermation of the planetaryring gear the HPG gearheadautomaucally compensatesfor gear tooth wear 81 Dellisays This helps ensure con-sistent backlash throughoutthe rated life of the gearbox
The H~ Series planetarygearheads have standardbacklash of less than 3 arc-minutes and they can beordered with 1 arc-minute ofbacklash as an option Theyare available in ratios from51 to 331
Cirele3mwwwpow9rrsnsmlssloncom bull wwwge8rtechnQJoycom bull GEAR TECHNOLOGYmiddotmiddot MAYJUNE 2001
MicmgearsFor Use In Tlhe
IHuman MachineIn a Hungarian lab using a
microscopes laser research-ers are creating gears androtors thinner than a humanhair ADd willie hair growsout of the body the re-searchers want to put theirgears and rotors into the bodyin microsoopic machines forconducting experiments
Its like the movie innerSpace wilh Dennis Quaidsays researcher p~ OrmosThe machines could be builtso small that they would fitinto blood vessels for analyz-ing blood
To create the gears androtors Onnos uses hardenedliquid photopolymer Butunlike the micropans and their
pos ible lise the material isntnearly as exotic
Dentists use it a letann os says The material isthe same as whats II ed fortooth fillings hardened withultraviolet light
Ormes developed the tech-nique with Fewr Galajda in alittle more than a year--Just now weare perfectingit Ormes acids that hed likero use the technique in lessthan a year to build everaltypes of machine
Willi a doctorate ill phys-ics Ormos belongs to theHungarian Academy of Sci-ences and works at itsBiological Research Centrelocated in Szeged Ormos isdirector of the centres Insti-tnte of Biophy it Galajda istis doctoral snrdent
We study thephysics of
Created undBr II microscope threll rotan appear in front of the Dak-likeIJIIJ1Jc lif bullbullbull II 110mB n bairLivingsystems Ormes says Ormos and Galajdas gearsHe acids lliat theres a strong and rotors could be usedjndrive ill biology toward minia- that study as parts in micro-turizing which has a lot of scopic biochemical device promise in it The micromachines would be
bull accuracybull reliabilitybull maintolinCibilitybull Hexibilily performancebull and life cyde eest
AI Klingelnberg the point ofprecision is 10 help you controlyour gear manufocturing pro-cess and improve gearqudlitywith measuring systems thaIare benchmarks for
Klingelnberg measuringtechnology contaeLiebherr Gear Technology Co1465 Woodland DriveSaline MI4B 176-1259
_------------REVOLUTIONS------------_used ro investigate living sys-terns at a cellular level per-mitting the movement of indi-vidual ceIls-even individuallarge molecules Ormos says~ts a very precise tool thatcan be used in biology
With such machines scien-tists could introduce chemi-cals into cells manipulatetheir reactions and maintainthose cells environmentspumping different solutions todifferent regions They couldmeasure cell properties toselect certaia cells create achannel for transporting thosecells and transport the cellsindividually They could alsoremove compounds fromcells even destroy cells
The gears and rotors diam-eters can be as small as twomicrons A human hales diam-eter is about 100 microns At
two microns the parts canweigh as little as ]()LO grams
Ormos and GaIajda maketheir microparts by placingliquid photopolymer under amicroscope then moving acomputer-controlled laser fo-cus into the microscopeWhereverthe focus movesthe liquid becomes hardenedIf it moves in a gear shape thefocus makes a hardened gear
We can create a three-dimensionalobject that is ascomplicated as we wantOrmes says
DUI theres a wri nkle inthe technology that needs tobe ironed out
The micro gears are rotatedby the microrotors The micro-rotors are rotated by light
Its not easy to introducelight into the blood vesselsOmms says
But he adds there may be asolution to that problemOrmos explains that themachines in the body could bepowered by tightlfit wereintroduced effectively-via athin optic fiber for example
In similar research SandiaNational Laboratories in NewMexico has used chemicalmiddotelching to create microgearsand experimental micro-engines electric motors no
1 larger than a grain of sandOrmos started his research
j to understand how light causesI different trapped particles toj rotate But he later realizedi such light-induced rotationi could have useful applicationsI
1 It was not really the areaI
1 in which we were deliberately
II
moving he saysOnnos is unsure about the
techniques future-Whether
this can be commercialized ornot isnt clear Still he andOalajda are testing resins todecide which works best forcreating their gears and rotors
I think the possibilities arereally uolimited Ormes saysAnything that can be donewith larger machines can bedone with smaller ones too
Cirde302
Tbullbull V
If you found tIriI IfticfI ofinterest andor UIefuI
~
l1~~
Phone + 1-734-429-7225Fax 1-734-429-2294wwwpointofprecisioncominfopointofprecisioncom
bull 1INDUSTRV NEWS _
Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
S86 HilliardStreet RO Box 1898 Manchester CT06045-1898 USATelephone 86() 1649-0000 bull Fax 860 645-629g
Home Page httpwwwpurdytransmissionscomf-Mail salespurrlytransmissonsfOffl
Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
Fifty years or VARI-ROLL applications providebull Production Composite Inspectionbull Custom Design amp Build Part Gear Mounting Fixturesbull Standard Mounting Fixtures - Spurs Helicals Pinion Shafts
Worms Throated Worms Bevels Internals
When coupled with the VARI-PC Composite Gear AnalysisSystem will providebull Reduced Inspection Cost Improved Accuracy Historical Record Keepingbull Serialization of Partsbull Interface to SPC programsExperience the difference See why customers worldwide havechosen the VARI-ROLUVARImiddotPC For further informationplease contact us
Precision Gage ce Inc100 Shore Drive Burr Ridge IL 60521
630-655-2121 Fax630-6S5-3073wwwpredsiongagecocom
United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
CIRCLE 1Ji
ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
Will YoI TIIiIk bullbullIf you found 1his column of inbaIt lIIdIoruseful pIe
If did notcn forflll coIumn _
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If you would like to mpond to this or anyother article In tltil adlllon of 60rTMhntw=faxvour ~totheIIlIfIdon If SIDU manqlnt edIIur ItIMJ437-1818 or I8ftd melII1D ~com
16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
S- Amcricllinc
Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
far __ illfonnalion eIIouI bull prIIIiucI DIIHrYiCJ JdHftIMd Ii hil iUIIII IIf 6_rfthohlfr I~-IM appropriate IIIUIIIber IIIIM lIIdr IInpg_ Callli MIlput ilia clrd in Ihe lIIIiI
11IYIDURWID IpoundADERIIESPONSE SYSTEMIIGoio wwwg bullbull nchlHlltlflyct1tJlmlrtm III Irlqlllll1 additiDnal infDmIationram Iny dverti r in hil iUlle Yow IrlqPesl will bullbull IIId til the Idvertiserwithl 24 bllm IDlluper-fU1 tllmaround I
IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
AIW Sy5lcmsAero Gar [nc
AGMAAja M~ Corp
AmmCllll MeIlll T~1l Co
Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
1_1 I)CiuIG~tIJ TlaquohnoIDV
Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
TIle Gleason WollksHolroyd
lndex Technologies lee
Inducloheai
lnsco Corplnterstate Tool CorpTW H~ltIlandKim ~lnberg S(IIme GmbHKprOf AlneriQ LLCKoro Sluupening ServiceKrei~r~hleCoonl Ine
Mew Media loeb amp More
MiCroGCATMidwest Gear amp Tool IncMidWeIgtlGeM Corp
acbil Mrchjning Techno[ogy Co
iagllIll Gear Corp
Nona Gear Failure Semiruur
On-Iine ServIlCS Inc
Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
Profile Engmccnog IncPru-Oew Co locThe Purdy Corp
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For Long runs we Offer the unique lIebherr CBN grindingprecess with full SPC Quality cOrtroland documentation
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CIRCLE 1141
TooHnk Engineeringoffers hydraulic arbors
made of a lightmetal alloy that
weigh up to70 less thana comparable
steel arborFeather lighthydraulicarbors can bemanufactured wilhrunout as low as2 microns The clampingsleeves are replaceabte Thistoolingl is suitable for measuringtesting balancinggear grindingand other applications
T_~O _--UIoIt--~-- ~~-~-~_ _ -1IIrIndIrit bull T-g bull LDbull OD ~-IumIn~
Toolink IEngineelling2870 Wilderness FI_
Boulder CO B030 IIgtt 3039388570
FAX 3039388572
powrrrIIM$4IOIIcom gulchnologycom bull GEAR TECHNOLOGY bull MAYJUNE 2DDI U
An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
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WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
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For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
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Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
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and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
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COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
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GLEASON IINTRODUCESTIHE-IELIECTRONIC
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A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
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HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
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IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
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CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
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Direct your inquiries toRon lfIumphrerGeneral Manage
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HOB SHARPENINGSERVICE
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bull THIN RLM COATINGSWest Branch Industries
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SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
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Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
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For information alld quoteplease cnntact us at the following
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Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
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PICK UP AN[I DELIVERY IN MANY AREAS
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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MAYJUNE 2001
FEATURES
The Journal of Gear Manufacturing
FOCUS ON GEAR DESIGN
211
DEPARTMENTS
11
56
Talking On Nature Three IGearCompanies And Their End-ProductsA look at several gear manufacturers with special products on the side 18
IGearbox ~ieldl Pedormance from a IRebuUders PerspectivelTips on gearbox design from someone whos seen gearbox failures 22
Gealr Design Speciall Section 27
Design Formulas for Evaluating Contact Stress in Generalized IGearPairsDetermining contact stress no matter the gear type 3
alA CalcullatingllDynamic Loads Sizingl Worm Gearsand figuringl Geometry factorsTechnical editor Robert Errichello answers your design-related questions 39
load IDistribution lin IPIanetaryGearsPredicting the dynamic behavior of planetary gear systems 41
Publishers PageFinding your core competency 7
IRevolutionsA new planetary gear system and microgears 11
Industry NewsWhats happening in the gear industry 15
Adveniser IindexGet information from advertisers by using the response card or going online l1
Technical CalendarDont mi s these important upcoming events 46
CD~ROMBuyers Guiide FormsFREE USTlNGS for gear-industry companies 41
Product NewsThe latest products for gear design manufacturing and testing 150
literalllre MartFree brochures and catalogs from our advertisers 52
IClassifiedsServices Help Wanted and more 54
AddendumGear Fashion 56
VOL 18 NO3I GEAR TECHNOLOGV Tn Jourtllll or GolOr
Manu[aclurlllg (lSSN 01-13-6858) pubUhed bunonth-Iy by RaJdnJI Publishing Inc bull 1421 I~u Avenue POBox 1426 Elk Greve Village IL 600071amp471437-6604Cove price S~OO US rioltlJoaI postage paid alArlington HeIghtamp ILbull and 31 eddmonnl mailing offieeRandall Publishing makes eety ffort 10 ensure lhallhltprocesses descnbed in GEAR TECHNOLOltiY conformto soond engmecringpraaioe Neilher the authors IlOI thepublisher can be hed responsible for IJIjuri~s sustainedtill foil tho procedllrtS desenbed PostmasterSend address change to GEAR TECHNOLOGY Jcurnal of Gear Manufacturing 142~ Lum Avonue POBo 1426 Elk Grov ViUogelL 60007 OConlents copy-righted hy RANDALL PUB[JSHlNG TNC 2001 Nopart of this publication may be reproduced or uansmluedin any r or by any means olccllDic or 1llOclJanioaIincfudmg pOOllymg ncordioB or by any informationstorage and relrieval system withOUJEpermission in wrtt-Log ampom be publisber Cootents 0( ads IOIljecl 10
CIRC(E136 LPo_b_lilhr_middot_ _pprDi__Ill JI
4 MAYJUNE 2001 bull GEAR TECHNOLOGY bull ww~98rt9chngycom wwwpowertransmlssloncom
OLS
EDITORIALPublisher amp Editor-in-CDief
Michael Goldstein
Managjng Editor WilIiam R Stott
Associate Editor Joseph L Hazelton
Editorial Consultant Paul R Goldstein
TeChnical EditorsRobert Errichello
Don McVittieRobert E Smith
Dan Thurman
ARTArt Dirtttor Jean Bartz
ADVERTISINGAdvertising Manager Patricia Flam
Advertising Coordinator Susan Brandl
CIRCULATIONICirculation Coordinator Dina Krauss
INTERNETInternet Editor Dan Mackenzie
Gear industry Home PagelMSalesPatricia Flam
powerrransmissUJ1MomTill SalesRobert Poll
RANDALL PUBLISHING STAFFPmident Michael Goldstein
Vice Presldent Richard GoldsteinAccounting Mary Lou Napadow
Phone 847-437-6604E-mailpeoplegeartechnologycom
Web wwwgeartechnologycomwwwpowertransmi~sioncom
BIPA_11OML
W
INACHi
G10 ba I Experti seFor All Applications
NACHI MACHINING T-eCHINOlOGY co17500 Twenty-Three Mi Ie Road Macomb Michigan 48044-1 103Phone (810)-263-0100 Fax (810)-263-4571 WIMnachimtccom
NACHI MACHINING TECHNOLOGY CO
Combining over 140 years I)f processmachine and tool experience enables NachiliMachining Technology Co to maintainiindustry leadership by proviiding customerswith the best practices manufatctuningsolutions
For the finest products penormence serviceand global support you can rely on NachiMTCto meet your application need today andtomorrow
Broach nd GearFinishing ProductsBroacJlIna
VerticalHOrizontalPolSurfaceBlind SplineVel1caJ Wo Transs
Geal 500vingRoll FormingRoll FinishingHobblngTool SharpeningHoningGeBlnspectionForm Gnndlng
CIRc~n4
_-----------IIPUBUSHERS IPAGiE 1 _
Co CoConcentrating on the CllAdal Components
Co Keep Yow CompanyCompe+i+ive
Rodgers and Hammerstein producedorne of Americas most memorable and
lasting songs in musical theater lyricistOscar Hammerstein IIonce aid of com-poser Richard Rodgers I hand him alyric and get out of his way Hammer-stein knew what Rodgers was good atand vice versa and each trusted his part-ner Their partnership was 0 successfulthat you can scarcely think of one manwithout the other
Musical composers arent the onlyones who form uccessful partnership mntodays manufacturing world partner-ships arealmo t a necessity Originalequipment manefacturers have competi-Lion not only from other manufacturersof similarequipment but 3110 from man-ufacturers of the components that go intotheitrequipment and the service pro-viders who process some of those com-ponems along the way
Ron Davi of Caterpillar Tnc madethis point at the recent annual meetingof the American Gear ManufacturersAs ociation Davis works in Caterpil-lars busine s administration divisionwhich help decide when to manufac-ture components in-house and when tooutsource them
Caterpmarequipment require abroad range of gear products includingtransmission shafts straight and spiralbevel gears planet gears sun gears andfinal drive ring gears They use largequantities of both machined and powdermetal gears
But Caterpillar cant hope to staycompetitive by rnanufaciuri ng all of itscomponents when other companies spe-cialize in manufacturing some of thosecomponents Davis says
The challenge is to decide whichcomponents and manufacturing process-es give Caterpillar the greatest competi-tive advantage when manufactured in-house and which give them the greatestcompetitive advantage when outsourcedOf course the ccmpanyexamines factorssuch as cost quality and customer satis-faction when considering competitiveadvantage Another factor is whetherCaterpillar has special expertise in man-ufacturing a particular component Thecompany also examines various risk cri-teria whether a part requires proprietarytechnology whether its an aftermarket-critical component or whether its time-to-market is critical
Those components that give them thegreatest competitive advantage whenmanufactured in-house are part of Cat-erpillars core competency Outsourcingthose components could lower the quali-Iy of the end-product make it moreexpensive or otherwise worsen the com-panys position in the marketplaceComponent that are not a part ofCaterpillars core competency might bebetter manufactured by others special-ists who can lower the costs improve thequality or both Outsourcing those nOI1-
core components also affords Caterpillarthe opportunity to devote its ownresources to improving those processesand products that are part of its covecompetency
Many of Caterpillars less criticalhigh-volume components such as enginegears are generally outsourced Criticalcomponents such as large transmissionsor filial drive gears are generally manu-factured in-house Medium-duty compo-nents such as small axles and small
transmissions are mixed between in-house manufacturing and outsourcing
Some of the ontsoureed gears aremanufactured by Avon Gear Co a divi-sion of Okubo Gear Co Ltd inRochester Hill MI At the AGMA meet-ing ] had the chance to talk with AvonGears president Aaron Remsing
According to Rem ing there was alime not long ago when Avon Gear hada near-death experience Business wasdown the company had just moved intoa new expensive building and thefuture wa uncertain Avon Gear had todo some soul-searching about its busi-ness Management wa forced to thinkabout the companys capabilities andreinvent the way that it obtained newbusiness Rernsing says The answer layin examining the companys own corecompetencies
Avon Gear knew it had the technicalexpertise equipment and experience tomanufacture certain sizes Iypes andquantities of gears of excellcru qualityand at competitive prices Instead ofwaiting for orders to come in Remsing
wlO powertransmuoncom bull f1OfgllarrechnoJogycom bull GEAR TECHNOLOGY 11IYfJUNE 2001 7
PUBLISHERS PAGEsays the company began approachingthose customers who could best takeadvantage of Avon Gears core compe-tencies One of those companies wasCaterpillar
By making a commitment to special-ize in a certain type of gear for a certainmarket segment Avon Gear was able tocapture Caterpillars business That busi-ness in tum allowed the company anopportunity to invest in new equipment
and training to provide even greater com-petitive advantage
Today according to Davis AvonGear is one of the most important sup-pliers for Caterpillars transmissionbusiness unit Working together thecompanies are able to provide theworld-class manufacturing quality andpricing on gear components that helpkeep Caterpillars equipment competi-tive in the world market Furiliermore
bullIng
Remove nicks buns hest treat scaleand Improve gear tooth surface
Onr 30 J8IlI ago morllaar1lalll developed the gelDbilihlmidlddDglllllllilnnJllOC8llPat JOU trust In tbe people who Invented the process
MAatlNE FEATURESINCLUDEbull Fully automated systemsbull High speed machinesbull Patented Gerac
Oscillation Systembull Automatic spherical
position Ingbull Trl-varlable die designbull Horizontal or vertical axis
machinesbull Variety of gear types
For additional information on IhHuBurnishingandor Functional flfiu
Inectionvisit our website ottIVIIVw ilWgearscom
ITP1tl HeartlandWorkilll9 components 01 theHorizontal Bumisher
1205 36th Avenue WestAlexandria MN 56308 USA
Ph (320) 762-8782Fax (320) 782-5280
E-mail ItwgeaISOrea-alpoom
8 MAYJU NE 2001 GEAFi TECHNOLOGYmiddot www9Ilartllchnolo9ycom bull wWWpowllrtransmissioncom
~c~l(JoldsteinPublisher amp Editor-in-Chief
the processes machines and expertisedeveloped by Avon Gear have given thecompany the ability to sell gears ofworld-class quality and price to othercustomers with similar needs
In fact Davis saysthe partnershipbetween these two companies has devel-oped into one of mutua] trust and plan-ning Like most successful partnershipsits now in the best interest of each partythat the other doesnt fail
Like Caterpillar and Avon Gear eachof our own companies has core compe-tencies-things that are central to ourbusiness which years of working in cer-tain areas allow us to do better than othercompanies without the same focusFinding those things concentrating onthem and expanding on them can helpmake us more successful
Not finding and developing your corecompetency can have the opposite effectIts true that some companies will bemore focused than others But even themost generalist of companies has corecompetencies For example a general-purpose gear job shop with a broad rangeof equipment and tooling might not seemto have a specific niche Neverthelessthat same company might specialize infast turnaround design assistance orextremely high quality each of whichcould be developed for greater competi-tive advantage in certain marketplaces
You can learn more about your corecompetencies by choice or by necessityIf you do so by choice perhaps you II beable to make intelligent decisions aboutyour companys operations as Caterpil-lar did However if you wait you may beforced to learn about your core compe-tencies the hard way Perhaps youll beable to act quickly enough to save yourcompany as Avon Gear did But thenagain
For 96 years the Bodine name has symbollized quality in power transmissionand motlon control IBodine EIectric Company pioneered the concept ot fracticnalhorsepower motors with integrall gear reducers We calrefully guard our reputationfor producing the quietest smoothest Iiongest-life products in the industry
Now you can tnccrporate those same higlhstandards of qualityrellabtlltyand on-time deillivelry iinto your products that require filneand medium pitch open gears from hundreds to hundreds oftLo - - - ~ -d -nousancs
Bodine Gear Manufacturing employs state-of-the-art eNG gearmanufactuning and inspection technology with in-depthengineening support to service your most demandinQappucattons For skived gears we can be your most competitiivecompetent source
To learn more about Bodiine Gear Manufacturing and get your Free Bodiine Gears capvisit ww-wBodineGearscomFreeCaphtm or call toll flree 877-4GEARS9
Sales Representative inquiries welcome
CIRetIE 109
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Theres only one way to ensure thatthe gears you produce win always deliversuperior and quiet performance Make suretheyre bred from quaUty stock
Dura-Bars continuous-cast gray and ductileiron performs like free-machining steel with anImportantadded bonus - quieter operation
Like steel Dura-Bar can he austemperedthrough-hardened flame-hardened or induction-hardened for added wear resistance Butthesuperior noise and vibration damping characteristicsof Dura-Bar make for quieter runninggears AndDura-Bar is 10Ughter than steel
Dura-Bar round bars are avatlable In diametersnnging from 58~ to 20 and lengths of 6-20 So youwont need to make major changes in your machining equipment And our extensive mventory means Dura-Bar is available now - when you need U
Wben Its quaUtymaterial quiet performance and quick deUverythatcount look to continuous-cast Dura-Bar for your gear production needs
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REVOLUTIONS -- _
Hlarmonic ConceptsJazz lp
Planetary DesiglnIn the world of planetary
servo drives precision iseverything Advertisementsabound fOJ ervo gear driveswith extremely low or evenzere backlash With that typeof drive in high demand man-ufacturers have done every-thing they can to tighten theirdesigns-thmugh more exact-ing tolerances tighter assem-bly and better materials
Instead of tightening onemanufacturer of planetaryservo drives has tried loosen-
mg in order [0 provide the lowbacklash that manufacturers ofrobotics and other precise posi-
tioning equipment requireThat loosening bas nothing
te do with the manufacturingtolerances or assembly Pre-cision manufacturing is stillrequired Ithas to do with atype of flexibility borrowedfrom a related technologyharmonic drive gearing
Harmonic drive gearinghas long been known for itslow backlash high precisionand compact design Har-monic drive systems use a cir-cular spline a flex spline and
Cut-away view of the HPG gear drive from HIl Systems
me HPG drive includes II 11111 lIear 10 cantro bacldash(defoRnltion 8xallllerated for mustrative purposes
wavegenera~or to createextremely high ratios in a sin-gle reduction One of theadvantages of the harmonicdrive system is that the flexspline deforms as it rotates tokeep its teeth fully loadedagainst the circular spline alaU times
Engineers at HD Systems ofHauppauge NY haveliguredout how to apply the deforma-tion concept of harmonic drivesystems to planetary gears aswell Instead of a flexible imlerspline bull the HPG harmonicplanetary gearheads use aflexible outer ring gear to pre-load the gearset
The flexible outer ringgear of the HPG gearheadcreates a continually adju l-ing backlash compensationmethod The ring gear is thin-ner in the radial directionthan a typical ring gear Thismakes it radjaUy flexible yettorsionally stiff says HDSystems marketing managerBrian St Denis As normal
Wecome to Revolu-
Iions th column tIItbrings you the Illtest
most up-to-dBtl ndeasY-Io-read informll-
tion bout the people
nd technology of thegell industry Revolu-
Uons welcomes OUsubmissions PleBSe
sefid them to Gear
Technologv PO Box1426 flk Grore VillageIt 60009 or fx (HI)
431-6618 If youd like
more infomllltion sbout
flY of the articles that
appellrpiliS cirelli theappropiate number on
the Reader Service Card
gear wear occurs any in-crease in space between the
jteeth is immediately compen- Isated by the preload in the ring gear The concept is as if Ithe ring gear is a spring in the Iradial direction
The system employed byHD Systems has a huge advan-tage over those commonlyemployed by other maaufac-turers says St Denis Thebackla h of the HPG drivewont deteriorate over time
One method commonlyemployed toprovide low orzero backlash ill planetarygear systems is to create atight fit between all of thegears However this methodis subject to gear tooth wearand over the life of the gear-box the backl3sll can increasesignificantly
Another method is to usepreloaded bevel gears as panof the mechanism Shimsforce the bevel gears togetheraxially which forces a raclialpreload in the planetary gearsBacklash in this type of sys-tem also increases over timebecause of gear tooth wear
Because of the flexibledefermation of the planetaryring gear the HPG gearheadautomaucally compensatesfor gear tooth wear 81 Dellisays This helps ensure con-sistent backlash throughoutthe rated life of the gearbox
The H~ Series planetarygearheads have standardbacklash of less than 3 arc-minutes and they can beordered with 1 arc-minute ofbacklash as an option Theyare available in ratios from51 to 331
Cirele3mwwwpow9rrsnsmlssloncom bull wwwge8rtechnQJoycom bull GEAR TECHNOLOGYmiddotmiddot MAYJUNE 2001
MicmgearsFor Use In Tlhe
IHuman MachineIn a Hungarian lab using a
microscopes laser research-ers are creating gears androtors thinner than a humanhair ADd willie hair growsout of the body the re-searchers want to put theirgears and rotors into the bodyin microsoopic machines forconducting experiments
Its like the movie innerSpace wilh Dennis Quaidsays researcher p~ OrmosThe machines could be builtso small that they would fitinto blood vessels for analyz-ing blood
To create the gears androtors Onnos uses hardenedliquid photopolymer Butunlike the micropans and their
pos ible lise the material isntnearly as exotic
Dentists use it a letann os says The material isthe same as whats II ed fortooth fillings hardened withultraviolet light
Ormes developed the tech-nique with Fewr Galajda in alittle more than a year--Just now weare perfectingit Ormes acids that hed likero use the technique in lessthan a year to build everaltypes of machine
Willi a doctorate ill phys-ics Ormos belongs to theHungarian Academy of Sci-ences and works at itsBiological Research Centrelocated in Szeged Ormos isdirector of the centres Insti-tnte of Biophy it Galajda istis doctoral snrdent
We study thephysics of
Created undBr II microscope threll rotan appear in front of the Dak-likeIJIIJ1Jc lif bullbullbull II 110mB n bairLivingsystems Ormes says Ormos and Galajdas gearsHe acids lliat theres a strong and rotors could be usedjndrive ill biology toward minia- that study as parts in micro-turizing which has a lot of scopic biochemical device promise in it The micromachines would be
bull accuracybull reliabilitybull maintolinCibilitybull Hexibilily performancebull and life cyde eest
AI Klingelnberg the point ofprecision is 10 help you controlyour gear manufocturing pro-cess and improve gearqudlitywith measuring systems thaIare benchmarks for
Klingelnberg measuringtechnology contaeLiebherr Gear Technology Co1465 Woodland DriveSaline MI4B 176-1259
_------------REVOLUTIONS------------_used ro investigate living sys-terns at a cellular level per-mitting the movement of indi-vidual ceIls-even individuallarge molecules Ormos says~ts a very precise tool thatcan be used in biology
With such machines scien-tists could introduce chemi-cals into cells manipulatetheir reactions and maintainthose cells environmentspumping different solutions todifferent regions They couldmeasure cell properties toselect certaia cells create achannel for transporting thosecells and transport the cellsindividually They could alsoremove compounds fromcells even destroy cells
The gears and rotors diam-eters can be as small as twomicrons A human hales diam-eter is about 100 microns At
two microns the parts canweigh as little as ]()LO grams
Ormos and GaIajda maketheir microparts by placingliquid photopolymer under amicroscope then moving acomputer-controlled laser fo-cus into the microscopeWhereverthe focus movesthe liquid becomes hardenedIf it moves in a gear shape thefocus makes a hardened gear
We can create a three-dimensionalobject that is ascomplicated as we wantOrmes says
DUI theres a wri nkle inthe technology that needs tobe ironed out
The micro gears are rotatedby the microrotors The micro-rotors are rotated by light
Its not easy to introducelight into the blood vesselsOmms says
But he adds there may be asolution to that problemOrmos explains that themachines in the body could bepowered by tightlfit wereintroduced effectively-via athin optic fiber for example
In similar research SandiaNational Laboratories in NewMexico has used chemicalmiddotelching to create microgearsand experimental micro-engines electric motors no
1 larger than a grain of sandOrmos started his research
j to understand how light causesI different trapped particles toj rotate But he later realizedi such light-induced rotationi could have useful applicationsI
1 It was not really the areaI
1 in which we were deliberately
II
moving he saysOnnos is unsure about the
techniques future-Whether
this can be commercialized ornot isnt clear Still he andOalajda are testing resins todecide which works best forcreating their gears and rotors
I think the possibilities arereally uolimited Ormes saysAnything that can be donewith larger machines can bedone with smaller ones too
Cirde302
Tbullbull V
If you found tIriI IfticfI ofinterest andor UIefuI
~
l1~~
Phone + 1-734-429-7225Fax 1-734-429-2294wwwpointofprecisioncominfopointofprecisioncom
bull 1INDUSTRV NEWS _
Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
S86 HilliardStreet RO Box 1898 Manchester CT06045-1898 USATelephone 86() 1649-0000 bull Fax 860 645-629g
Home Page httpwwwpurdytransmissionscomf-Mail salespurrlytransmissonsfOffl
Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
Fifty years or VARI-ROLL applications providebull Production Composite Inspectionbull Custom Design amp Build Part Gear Mounting Fixturesbull Standard Mounting Fixtures - Spurs Helicals Pinion Shafts
Worms Throated Worms Bevels Internals
When coupled with the VARI-PC Composite Gear AnalysisSystem will providebull Reduced Inspection Cost Improved Accuracy Historical Record Keepingbull Serialization of Partsbull Interface to SPC programsExperience the difference See why customers worldwide havechosen the VARI-ROLUVARImiddotPC For further informationplease contact us
Precision Gage ce Inc100 Shore Drive Burr Ridge IL 60521
630-655-2121 Fax630-6S5-3073wwwpredsiongagecocom
United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
CIRCLE 1Ji
ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
Will YoI TIIiIk bullbullIf you found 1his column of inbaIt lIIdIoruseful pIe
If did notcn forflll coIumn _
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16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
S- Amcricllinc
Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
far __ illfonnalion eIIouI bull prIIIiucI DIIHrYiCJ JdHftIMd Ii hil iUIIII IIf 6_rfthohlfr I~-IM appropriate IIIUIIIber IIIIM lIIdr IInpg_ Callli MIlput ilia clrd in Ihe lIIIiI
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IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
AIW Sy5lcmsAero Gar [nc
AGMAAja M~ Corp
AmmCllll MeIlll T~1l Co
Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
1_1 I)CiuIG~tIJ TlaquohnoIDV
Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
TIle Gleason WollksHolroyd
lndex Technologies lee
Inducloheai
lnsco Corplnterstate Tool CorpTW H~ltIlandKim ~lnberg S(IIme GmbHKprOf AlneriQ LLCKoro Sluupening ServiceKrei~r~hleCoonl Ine
Mew Media loeb amp More
MiCroGCATMidwest Gear amp Tool IncMidWeIgtlGeM Corp
acbil Mrchjning Techno[ogy Co
iagllIll Gear Corp
Nona Gear Failure Semiruur
On-Iine ServIlCS Inc
Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
Profile Engmccnog IncPru-Oew Co locThe Purdy Corp
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GROUND GEARS- TeD or ren lhousandFor small to medium Quantities of spurs or helicals that have tomeet close-tolerance AGMA or DIN specs our Relshauer grindersand MampM gear analysis systems arelhe perfect combination
For Long runs we Offer the unique lIebherr CBN grindingprecess with full SPC Quality cOrtroland documentation
So whetller your needs are for lel1 or tens 01 thousands weinvite you to join the growing lst DIINSCO customers who rely onus lor consistent qua Irty reasonable costs and reliable delive ry
G PItONE 9q8~448~6368FAX918-448-511551WEB Inscocorplcomrnsco 412 Main Street Groton Massachusetts 01450
ORPORATION
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TooHnk Engineeringoffers hydraulic arbors
made of a lightmetal alloy that
weigh up to70 less thana comparable
steel arborFeather lighthydraulicarbors can bemanufactured wilhrunout as low as2 microns The clampingsleeves are replaceabte Thistoolingl is suitable for measuringtesting balancinggear grindingand other applications
T_~O _--UIoIt--~-- ~~-~-~_ _ -1IIrIndIrit bull T-g bull LDbull OD ~-IumIn~
Toolink IEngineelling2870 Wilderness FI_
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powrrrIIM$4IOIIcom gulchnologycom bull GEAR TECHNOLOGY bull MAYJUNE 2DDI U
An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
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WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
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H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
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May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
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AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
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May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
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THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
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(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
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D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
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_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
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Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
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We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
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New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
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Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
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New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
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CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
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NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
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RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
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SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
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lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
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For information alld quoteplease cnntact us at the following
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Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
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4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
MAYJUNE 2001
FEATURES
The Journal of Gear Manufacturing
FOCUS ON GEAR DESIGN
211
DEPARTMENTS
11
56
Talking On Nature Three IGearCompanies And Their End-ProductsA look at several gear manufacturers with special products on the side 18
IGearbox ~ieldl Pedormance from a IRebuUders PerspectivelTips on gearbox design from someone whos seen gearbox failures 22
Gealr Design Speciall Section 27
Design Formulas for Evaluating Contact Stress in Generalized IGearPairsDetermining contact stress no matter the gear type 3
alA CalcullatingllDynamic Loads Sizingl Worm Gearsand figuringl Geometry factorsTechnical editor Robert Errichello answers your design-related questions 39
load IDistribution lin IPIanetaryGearsPredicting the dynamic behavior of planetary gear systems 41
Publishers PageFinding your core competency 7
IRevolutionsA new planetary gear system and microgears 11
Industry NewsWhats happening in the gear industry 15
Adveniser IindexGet information from advertisers by using the response card or going online l1
Technical CalendarDont mi s these important upcoming events 46
CD~ROMBuyers Guiide FormsFREE USTlNGS for gear-industry companies 41
Product NewsThe latest products for gear design manufacturing and testing 150
literalllre MartFree brochures and catalogs from our advertisers 52
IClassifiedsServices Help Wanted and more 54
AddendumGear Fashion 56
VOL 18 NO3I GEAR TECHNOLOGV Tn Jourtllll or GolOr
Manu[aclurlllg (lSSN 01-13-6858) pubUhed bunonth-Iy by RaJdnJI Publishing Inc bull 1421 I~u Avenue POBox 1426 Elk Greve Village IL 600071amp471437-6604Cove price S~OO US rioltlJoaI postage paid alArlington HeIghtamp ILbull and 31 eddmonnl mailing offieeRandall Publishing makes eety ffort 10 ensure lhallhltprocesses descnbed in GEAR TECHNOLOltiY conformto soond engmecringpraaioe Neilher the authors IlOI thepublisher can be hed responsible for IJIjuri~s sustainedtill foil tho procedllrtS desenbed PostmasterSend address change to GEAR TECHNOLOGY Jcurnal of Gear Manufacturing 142~ Lum Avonue POBo 1426 Elk Grov ViUogelL 60007 OConlents copy-righted hy RANDALL PUB[JSHlNG TNC 2001 Nopart of this publication may be reproduced or uansmluedin any r or by any means olccllDic or 1llOclJanioaIincfudmg pOOllymg ncordioB or by any informationstorage and relrieval system withOUJEpermission in wrtt-Log ampom be publisber Cootents 0( ads IOIljecl 10
CIRC(E136 LPo_b_lilhr_middot_ _pprDi__Ill JI
4 MAYJUNE 2001 bull GEAR TECHNOLOGY bull ww~98rt9chngycom wwwpowertransmlssloncom
OLS
EDITORIALPublisher amp Editor-in-CDief
Michael Goldstein
Managjng Editor WilIiam R Stott
Associate Editor Joseph L Hazelton
Editorial Consultant Paul R Goldstein
TeChnical EditorsRobert Errichello
Don McVittieRobert E Smith
Dan Thurman
ARTArt Dirtttor Jean Bartz
ADVERTISINGAdvertising Manager Patricia Flam
Advertising Coordinator Susan Brandl
CIRCULATIONICirculation Coordinator Dina Krauss
INTERNETInternet Editor Dan Mackenzie
Gear industry Home PagelMSalesPatricia Flam
powerrransmissUJ1MomTill SalesRobert Poll
RANDALL PUBLISHING STAFFPmident Michael Goldstein
Vice Presldent Richard GoldsteinAccounting Mary Lou Napadow
Phone 847-437-6604E-mailpeoplegeartechnologycom
Web wwwgeartechnologycomwwwpowertransmi~sioncom
BIPA_11OML
W
INACHi
G10 ba I Experti seFor All Applications
NACHI MACHINING T-eCHINOlOGY co17500 Twenty-Three Mi Ie Road Macomb Michigan 48044-1 103Phone (810)-263-0100 Fax (810)-263-4571 WIMnachimtccom
NACHI MACHINING TECHNOLOGY CO
Combining over 140 years I)f processmachine and tool experience enables NachiliMachining Technology Co to maintainiindustry leadership by proviiding customerswith the best practices manufatctuningsolutions
For the finest products penormence serviceand global support you can rely on NachiMTCto meet your application need today andtomorrow
Broach nd GearFinishing ProductsBroacJlIna
VerticalHOrizontalPolSurfaceBlind SplineVel1caJ Wo Transs
Geal 500vingRoll FormingRoll FinishingHobblngTool SharpeningHoningGeBlnspectionForm Gnndlng
CIRc~n4
_-----------IIPUBUSHERS IPAGiE 1 _
Co CoConcentrating on the CllAdal Components
Co Keep Yow CompanyCompe+i+ive
Rodgers and Hammerstein producedorne of Americas most memorable and
lasting songs in musical theater lyricistOscar Hammerstein IIonce aid of com-poser Richard Rodgers I hand him alyric and get out of his way Hammer-stein knew what Rodgers was good atand vice versa and each trusted his part-ner Their partnership was 0 successfulthat you can scarcely think of one manwithout the other
Musical composers arent the onlyones who form uccessful partnership mntodays manufacturing world partner-ships arealmo t a necessity Originalequipment manefacturers have competi-Lion not only from other manufacturersof similarequipment but 3110 from man-ufacturers of the components that go intotheitrequipment and the service pro-viders who process some of those com-ponems along the way
Ron Davi of Caterpillar Tnc madethis point at the recent annual meetingof the American Gear ManufacturersAs ociation Davis works in Caterpil-lars busine s administration divisionwhich help decide when to manufac-ture components in-house and when tooutsource them
Caterpmarequipment require abroad range of gear products includingtransmission shafts straight and spiralbevel gears planet gears sun gears andfinal drive ring gears They use largequantities of both machined and powdermetal gears
But Caterpillar cant hope to staycompetitive by rnanufaciuri ng all of itscomponents when other companies spe-cialize in manufacturing some of thosecomponents Davis says
The challenge is to decide whichcomponents and manufacturing process-es give Caterpillar the greatest competi-tive advantage when manufactured in-house and which give them the greatestcompetitive advantage when outsourcedOf course the ccmpanyexamines factorssuch as cost quality and customer satis-faction when considering competitiveadvantage Another factor is whetherCaterpillar has special expertise in man-ufacturing a particular component Thecompany also examines various risk cri-teria whether a part requires proprietarytechnology whether its an aftermarket-critical component or whether its time-to-market is critical
Those components that give them thegreatest competitive advantage whenmanufactured in-house are part of Cat-erpillars core competency Outsourcingthose components could lower the quali-Iy of the end-product make it moreexpensive or otherwise worsen the com-panys position in the marketplaceComponent that are not a part ofCaterpillars core competency might bebetter manufactured by others special-ists who can lower the costs improve thequality or both Outsourcing those nOI1-
core components also affords Caterpillarthe opportunity to devote its ownresources to improving those processesand products that are part of its covecompetency
Many of Caterpillars less criticalhigh-volume components such as enginegears are generally outsourced Criticalcomponents such as large transmissionsor filial drive gears are generally manu-factured in-house Medium-duty compo-nents such as small axles and small
transmissions are mixed between in-house manufacturing and outsourcing
Some of the ontsoureed gears aremanufactured by Avon Gear Co a divi-sion of Okubo Gear Co Ltd inRochester Hill MI At the AGMA meet-ing ] had the chance to talk with AvonGears president Aaron Remsing
According to Rem ing there was alime not long ago when Avon Gear hada near-death experience Business wasdown the company had just moved intoa new expensive building and thefuture wa uncertain Avon Gear had todo some soul-searching about its busi-ness Management wa forced to thinkabout the companys capabilities andreinvent the way that it obtained newbusiness Rernsing says The answer layin examining the companys own corecompetencies
Avon Gear knew it had the technicalexpertise equipment and experience tomanufacture certain sizes Iypes andquantities of gears of excellcru qualityand at competitive prices Instead ofwaiting for orders to come in Remsing
wlO powertransmuoncom bull f1OfgllarrechnoJogycom bull GEAR TECHNOLOGY 11IYfJUNE 2001 7
PUBLISHERS PAGEsays the company began approachingthose customers who could best takeadvantage of Avon Gears core compe-tencies One of those companies wasCaterpillar
By making a commitment to special-ize in a certain type of gear for a certainmarket segment Avon Gear was able tocapture Caterpillars business That busi-ness in tum allowed the company anopportunity to invest in new equipment
and training to provide even greater com-petitive advantage
Today according to Davis AvonGear is one of the most important sup-pliers for Caterpillars transmissionbusiness unit Working together thecompanies are able to provide theworld-class manufacturing quality andpricing on gear components that helpkeep Caterpillars equipment competi-tive in the world market Furiliermore
bullIng
Remove nicks buns hest treat scaleand Improve gear tooth surface
Onr 30 J8IlI ago morllaar1lalll developed the gelDbilihlmidlddDglllllllilnnJllOC8llPat JOU trust In tbe people who Invented the process
MAatlNE FEATURESINCLUDEbull Fully automated systemsbull High speed machinesbull Patented Gerac
Oscillation Systembull Automatic spherical
position Ingbull Trl-varlable die designbull Horizontal or vertical axis
machinesbull Variety of gear types
For additional information on IhHuBurnishingandor Functional flfiu
Inectionvisit our website ottIVIIVw ilWgearscom
ITP1tl HeartlandWorkilll9 components 01 theHorizontal Bumisher
1205 36th Avenue WestAlexandria MN 56308 USA
Ph (320) 762-8782Fax (320) 782-5280
E-mail ItwgeaISOrea-alpoom
8 MAYJU NE 2001 GEAFi TECHNOLOGYmiddot www9Ilartllchnolo9ycom bull wWWpowllrtransmissioncom
~c~l(JoldsteinPublisher amp Editor-in-Chief
the processes machines and expertisedeveloped by Avon Gear have given thecompany the ability to sell gears ofworld-class quality and price to othercustomers with similar needs
In fact Davis saysthe partnershipbetween these two companies has devel-oped into one of mutua] trust and plan-ning Like most successful partnershipsits now in the best interest of each partythat the other doesnt fail
Like Caterpillar and Avon Gear eachof our own companies has core compe-tencies-things that are central to ourbusiness which years of working in cer-tain areas allow us to do better than othercompanies without the same focusFinding those things concentrating onthem and expanding on them can helpmake us more successful
Not finding and developing your corecompetency can have the opposite effectIts true that some companies will bemore focused than others But even themost generalist of companies has corecompetencies For example a general-purpose gear job shop with a broad rangeof equipment and tooling might not seemto have a specific niche Neverthelessthat same company might specialize infast turnaround design assistance orextremely high quality each of whichcould be developed for greater competi-tive advantage in certain marketplaces
You can learn more about your corecompetencies by choice or by necessityIf you do so by choice perhaps you II beable to make intelligent decisions aboutyour companys operations as Caterpil-lar did However if you wait you may beforced to learn about your core compe-tencies the hard way Perhaps youll beable to act quickly enough to save yourcompany as Avon Gear did But thenagain
For 96 years the Bodine name has symbollized quality in power transmissionand motlon control IBodine EIectric Company pioneered the concept ot fracticnalhorsepower motors with integrall gear reducers We calrefully guard our reputationfor producing the quietest smoothest Iiongest-life products in the industry
Now you can tnccrporate those same higlhstandards of qualityrellabtlltyand on-time deillivelry iinto your products that require filneand medium pitch open gears from hundreds to hundreds oftLo - - - ~ -d -nousancs
Bodine Gear Manufacturing employs state-of-the-art eNG gearmanufactuning and inspection technology with in-depthengineening support to service your most demandinQappucattons For skived gears we can be your most competitiivecompetent source
To learn more about Bodiine Gear Manufacturing and get your Free Bodiine Gears capvisit ww-wBodineGearscomFreeCaphtm or call toll flree 877-4GEARS9
Sales Representative inquiries welcome
CIRetIE 109
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Quieter GearsEngineered Metals
Theres only one way to ensure thatthe gears you produce win always deliversuperior and quiet performance Make suretheyre bred from quaUty stock
Dura-Bars continuous-cast gray and ductileiron performs like free-machining steel with anImportantadded bonus - quieter operation
Like steel Dura-Bar can he austemperedthrough-hardened flame-hardened or induction-hardened for added wear resistance Butthesuperior noise and vibration damping characteristicsof Dura-Bar make for quieter runninggears AndDura-Bar is 10Ughter than steel
Dura-Bar round bars are avatlable In diametersnnging from 58~ to 20 and lengths of 6-20 So youwont need to make major changes in your machining equipment And our extensive mventory means Dura-Bar is available now - when you need U
Wben Its quaUtymaterial quiet performance and quick deUverythatcount look to continuous-cast Dura-Bar for your gear production needs
DURA~BARreg 1-S00BAR-MILL (227-6455) - 815-338-7800 -Fax 815-338middot15492100 West Lake Shore Drive Woodstock H-60098-7497Web Site wwwdiutamiddotbalcom bull E-mail salesdura-barcQmContinuous Cast Iron Bar Stock
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REVOLUTIONS -- _
Hlarmonic ConceptsJazz lp
Planetary DesiglnIn the world of planetary
servo drives precision iseverything Advertisementsabound fOJ ervo gear driveswith extremely low or evenzere backlash With that typeof drive in high demand man-ufacturers have done every-thing they can to tighten theirdesigns-thmugh more exact-ing tolerances tighter assem-bly and better materials
Instead of tightening onemanufacturer of planetaryservo drives has tried loosen-
mg in order [0 provide the lowbacklash that manufacturers ofrobotics and other precise posi-
tioning equipment requireThat loosening bas nothing
te do with the manufacturingtolerances or assembly Pre-cision manufacturing is stillrequired Ithas to do with atype of flexibility borrowedfrom a related technologyharmonic drive gearing
Harmonic drive gearinghas long been known for itslow backlash high precisionand compact design Har-monic drive systems use a cir-cular spline a flex spline and
Cut-away view of the HPG gear drive from HIl Systems
me HPG drive includes II 11111 lIear 10 cantro bacldash(defoRnltion 8xallllerated for mustrative purposes
wavegenera~or to createextremely high ratios in a sin-gle reduction One of theadvantages of the harmonicdrive system is that the flexspline deforms as it rotates tokeep its teeth fully loadedagainst the circular spline alaU times
Engineers at HD Systems ofHauppauge NY haveliguredout how to apply the deforma-tion concept of harmonic drivesystems to planetary gears aswell Instead of a flexible imlerspline bull the HPG harmonicplanetary gearheads use aflexible outer ring gear to pre-load the gearset
The flexible outer ringgear of the HPG gearheadcreates a continually adju l-ing backlash compensationmethod The ring gear is thin-ner in the radial directionthan a typical ring gear Thismakes it radjaUy flexible yettorsionally stiff says HDSystems marketing managerBrian St Denis As normal
Wecome to Revolu-
Iions th column tIItbrings you the Illtest
most up-to-dBtl ndeasY-Io-read informll-
tion bout the people
nd technology of thegell industry Revolu-
Uons welcomes OUsubmissions PleBSe
sefid them to Gear
Technologv PO Box1426 flk Grore VillageIt 60009 or fx (HI)
431-6618 If youd like
more infomllltion sbout
flY of the articles that
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gear wear occurs any in-crease in space between the
jteeth is immediately compen- Isated by the preload in the ring gear The concept is as if Ithe ring gear is a spring in the Iradial direction
The system employed byHD Systems has a huge advan-tage over those commonlyemployed by other maaufac-turers says St Denis Thebackla h of the HPG drivewont deteriorate over time
One method commonlyemployed toprovide low orzero backlash ill planetarygear systems is to create atight fit between all of thegears However this methodis subject to gear tooth wearand over the life of the gear-box the backl3sll can increasesignificantly
Another method is to usepreloaded bevel gears as panof the mechanism Shimsforce the bevel gears togetheraxially which forces a raclialpreload in the planetary gearsBacklash in this type of sys-tem also increases over timebecause of gear tooth wear
Because of the flexibledefermation of the planetaryring gear the HPG gearheadautomaucally compensatesfor gear tooth wear 81 Dellisays This helps ensure con-sistent backlash throughoutthe rated life of the gearbox
The H~ Series planetarygearheads have standardbacklash of less than 3 arc-minutes and they can beordered with 1 arc-minute ofbacklash as an option Theyare available in ratios from51 to 331
Cirele3mwwwpow9rrsnsmlssloncom bull wwwge8rtechnQJoycom bull GEAR TECHNOLOGYmiddotmiddot MAYJUNE 2001
MicmgearsFor Use In Tlhe
IHuman MachineIn a Hungarian lab using a
microscopes laser research-ers are creating gears androtors thinner than a humanhair ADd willie hair growsout of the body the re-searchers want to put theirgears and rotors into the bodyin microsoopic machines forconducting experiments
Its like the movie innerSpace wilh Dennis Quaidsays researcher p~ OrmosThe machines could be builtso small that they would fitinto blood vessels for analyz-ing blood
To create the gears androtors Onnos uses hardenedliquid photopolymer Butunlike the micropans and their
pos ible lise the material isntnearly as exotic
Dentists use it a letann os says The material isthe same as whats II ed fortooth fillings hardened withultraviolet light
Ormes developed the tech-nique with Fewr Galajda in alittle more than a year--Just now weare perfectingit Ormes acids that hed likero use the technique in lessthan a year to build everaltypes of machine
Willi a doctorate ill phys-ics Ormos belongs to theHungarian Academy of Sci-ences and works at itsBiological Research Centrelocated in Szeged Ormos isdirector of the centres Insti-tnte of Biophy it Galajda istis doctoral snrdent
We study thephysics of
Created undBr II microscope threll rotan appear in front of the Dak-likeIJIIJ1Jc lif bullbullbull II 110mB n bairLivingsystems Ormes says Ormos and Galajdas gearsHe acids lliat theres a strong and rotors could be usedjndrive ill biology toward minia- that study as parts in micro-turizing which has a lot of scopic biochemical device promise in it The micromachines would be
bull accuracybull reliabilitybull maintolinCibilitybull Hexibilily performancebull and life cyde eest
AI Klingelnberg the point ofprecision is 10 help you controlyour gear manufocturing pro-cess and improve gearqudlitywith measuring systems thaIare benchmarks for
Klingelnberg measuringtechnology contaeLiebherr Gear Technology Co1465 Woodland DriveSaline MI4B 176-1259
_------------REVOLUTIONS------------_used ro investigate living sys-terns at a cellular level per-mitting the movement of indi-vidual ceIls-even individuallarge molecules Ormos says~ts a very precise tool thatcan be used in biology
With such machines scien-tists could introduce chemi-cals into cells manipulatetheir reactions and maintainthose cells environmentspumping different solutions todifferent regions They couldmeasure cell properties toselect certaia cells create achannel for transporting thosecells and transport the cellsindividually They could alsoremove compounds fromcells even destroy cells
The gears and rotors diam-eters can be as small as twomicrons A human hales diam-eter is about 100 microns At
two microns the parts canweigh as little as ]()LO grams
Ormos and GaIajda maketheir microparts by placingliquid photopolymer under amicroscope then moving acomputer-controlled laser fo-cus into the microscopeWhereverthe focus movesthe liquid becomes hardenedIf it moves in a gear shape thefocus makes a hardened gear
We can create a three-dimensionalobject that is ascomplicated as we wantOrmes says
DUI theres a wri nkle inthe technology that needs tobe ironed out
The micro gears are rotatedby the microrotors The micro-rotors are rotated by light
Its not easy to introducelight into the blood vesselsOmms says
But he adds there may be asolution to that problemOrmos explains that themachines in the body could bepowered by tightlfit wereintroduced effectively-via athin optic fiber for example
In similar research SandiaNational Laboratories in NewMexico has used chemicalmiddotelching to create microgearsand experimental micro-engines electric motors no
1 larger than a grain of sandOrmos started his research
j to understand how light causesI different trapped particles toj rotate But he later realizedi such light-induced rotationi could have useful applicationsI
1 It was not really the areaI
1 in which we were deliberately
II
moving he saysOnnos is unsure about the
techniques future-Whether
this can be commercialized ornot isnt clear Still he andOalajda are testing resins todecide which works best forcreating their gears and rotors
I think the possibilities arereally uolimited Ormes saysAnything that can be donewith larger machines can bedone with smaller ones too
Cirde302
Tbullbull V
If you found tIriI IfticfI ofinterest andor UIefuI
~
l1~~
Phone + 1-734-429-7225Fax 1-734-429-2294wwwpointofprecisioncominfopointofprecisioncom
bull 1INDUSTRV NEWS _
Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
S86 HilliardStreet RO Box 1898 Manchester CT06045-1898 USATelephone 86() 1649-0000 bull Fax 860 645-629g
Home Page httpwwwpurdytransmissionscomf-Mail salespurrlytransmissonsfOffl
Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
Fifty years or VARI-ROLL applications providebull Production Composite Inspectionbull Custom Design amp Build Part Gear Mounting Fixturesbull Standard Mounting Fixtures - Spurs Helicals Pinion Shafts
Worms Throated Worms Bevels Internals
When coupled with the VARI-PC Composite Gear AnalysisSystem will providebull Reduced Inspection Cost Improved Accuracy Historical Record Keepingbull Serialization of Partsbull Interface to SPC programsExperience the difference See why customers worldwide havechosen the VARI-ROLUVARImiddotPC For further informationplease contact us
Precision Gage ce Inc100 Shore Drive Burr Ridge IL 60521
630-655-2121 Fax630-6S5-3073wwwpredsiongagecocom
United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
CIRCLE 1Ji
ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
Will YoI TIIiIk bullbullIf you found 1his column of inbaIt lIIdIoruseful pIe
If did notcn forflll coIumn _
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16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
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Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
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IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
AIW Sy5lcmsAero Gar [nc
AGMAAja M~ Corp
AmmCllll MeIlll T~1l Co
Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
1_1 I)CiuIG~tIJ TlaquohnoIDV
Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
TIle Gleason WollksHolroyd
lndex Technologies lee
Inducloheai
lnsco Corplnterstate Tool CorpTW H~ltIlandKim ~lnberg S(IIme GmbHKprOf AlneriQ LLCKoro Sluupening ServiceKrei~r~hleCoonl Ine
Mew Media loeb amp More
MiCroGCATMidwest Gear amp Tool IncMidWeIgtlGeM Corp
acbil Mrchjning Techno[ogy Co
iagllIll Gear Corp
Nona Gear Failure Semiruur
On-Iine ServIlCS Inc
Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
Profile Engmccnog IncPru-Oew Co locThe Purdy Corp
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GROUND GEARS- TeD or ren lhousandFor small to medium Quantities of spurs or helicals that have tomeet close-tolerance AGMA or DIN specs our Relshauer grindersand MampM gear analysis systems arelhe perfect combination
For Long runs we Offer the unique lIebherr CBN grindingprecess with full SPC Quality cOrtroland documentation
So whetller your needs are for lel1 or tens 01 thousands weinvite you to join the growing lst DIINSCO customers who rely onus lor consistent qua Irty reasonable costs and reliable delive ry
G PItONE 9q8~448~6368FAX918-448-511551WEB Inscocorplcomrnsco 412 Main Street Groton Massachusetts 01450
ORPORATION
ISO 9001 IReglstered
CIRCLE 1141
TooHnk Engineeringoffers hydraulic arbors
made of a lightmetal alloy that
weigh up to70 less thana comparable
steel arborFeather lighthydraulicarbors can bemanufactured wilhrunout as low as2 microns The clampingsleeves are replaceabte Thistoolingl is suitable for measuringtesting balancinggear grindingand other applications
T_~O _--UIoIt--~-- ~~-~-~_ _ -1IIrIndIrit bull T-g bull LDbull OD ~-IumIn~
Toolink IEngineelling2870 Wilderness FI_
Boulder CO B030 IIgtt 3039388570
FAX 3039388572
powrrrIIM$4IOIIcom gulchnologycom bull GEAR TECHNOLOGY bull MAYJUNE 2DDI U
An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
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WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
Solutions for yourgear manufacturingneeds~owefiedbySamputensil
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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Class 12bull Design assistance
availableFor more Information contact
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CERTIFIED
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(4a)
(4b)
(Sa)
(5b)
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CIRCLEli1(6a)
_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
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FOR MORE INFORMATION CONTACTAMERICAN GEAR MANUIFACTURERS ASSOCIATIONbull PHONE (703) 684-0211bull FAX (703) 684-0242bull EMAIL GEAREXPOAGMAO Gbull WEBSITE WWWAGMAORGI bull-
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
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arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
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110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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Provides actual overballpin measurmenof any helical orgear or splin WiLU t-
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bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
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STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
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STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
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We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
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and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
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Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
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(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
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HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
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IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
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CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
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Midwest Gear ICOrp2182 E AurorallRd
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Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
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HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
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Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
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For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
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HOB SHARPIENIINGbull State-of-the-art eNC sharpening
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Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
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GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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New BItID11I CT OBOS--~
VOL 18 NO3I GEAR TECHNOLOGV Tn Jourtllll or GolOr
Manu[aclurlllg (lSSN 01-13-6858) pubUhed bunonth-Iy by RaJdnJI Publishing Inc bull 1421 I~u Avenue POBox 1426 Elk Greve Village IL 600071amp471437-6604Cove price S~OO US rioltlJoaI postage paid alArlington HeIghtamp ILbull and 31 eddmonnl mailing offieeRandall Publishing makes eety ffort 10 ensure lhallhltprocesses descnbed in GEAR TECHNOLOltiY conformto soond engmecringpraaioe Neilher the authors IlOI thepublisher can be hed responsible for IJIjuri~s sustainedtill foil tho procedllrtS desenbed PostmasterSend address change to GEAR TECHNOLOGY Jcurnal of Gear Manufacturing 142~ Lum Avonue POBo 1426 Elk Grov ViUogelL 60007 OConlents copy-righted hy RANDALL PUB[JSHlNG TNC 2001 Nopart of this publication may be reproduced or uansmluedin any r or by any means olccllDic or 1llOclJanioaIincfudmg pOOllymg ncordioB or by any informationstorage and relrieval system withOUJEpermission in wrtt-Log ampom be publisber Cootents 0( ads IOIljecl 10
CIRC(E136 LPo_b_lilhr_middot_ _pprDi__Ill JI
4 MAYJUNE 2001 bull GEAR TECHNOLOGY bull ww~98rt9chngycom wwwpowertransmlssloncom
OLS
EDITORIALPublisher amp Editor-in-CDief
Michael Goldstein
Managjng Editor WilIiam R Stott
Associate Editor Joseph L Hazelton
Editorial Consultant Paul R Goldstein
TeChnical EditorsRobert Errichello
Don McVittieRobert E Smith
Dan Thurman
ARTArt Dirtttor Jean Bartz
ADVERTISINGAdvertising Manager Patricia Flam
Advertising Coordinator Susan Brandl
CIRCULATIONICirculation Coordinator Dina Krauss
INTERNETInternet Editor Dan Mackenzie
Gear industry Home PagelMSalesPatricia Flam
powerrransmissUJ1MomTill SalesRobert Poll
RANDALL PUBLISHING STAFFPmident Michael Goldstein
Vice Presldent Richard GoldsteinAccounting Mary Lou Napadow
Phone 847-437-6604E-mailpeoplegeartechnologycom
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NACHI MACHINING T-eCHINOlOGY co17500 Twenty-Three Mi Ie Road Macomb Michigan 48044-1 103Phone (810)-263-0100 Fax (810)-263-4571 WIMnachimtccom
NACHI MACHINING TECHNOLOGY CO
Combining over 140 years I)f processmachine and tool experience enables NachiliMachining Technology Co to maintainiindustry leadership by proviiding customerswith the best practices manufatctuningsolutions
For the finest products penormence serviceand global support you can rely on NachiMTCto meet your application need today andtomorrow
Broach nd GearFinishing ProductsBroacJlIna
VerticalHOrizontalPolSurfaceBlind SplineVel1caJ Wo Transs
Geal 500vingRoll FormingRoll FinishingHobblngTool SharpeningHoningGeBlnspectionForm Gnndlng
CIRc~n4
_-----------IIPUBUSHERS IPAGiE 1 _
Co CoConcentrating on the CllAdal Components
Co Keep Yow CompanyCompe+i+ive
Rodgers and Hammerstein producedorne of Americas most memorable and
lasting songs in musical theater lyricistOscar Hammerstein IIonce aid of com-poser Richard Rodgers I hand him alyric and get out of his way Hammer-stein knew what Rodgers was good atand vice versa and each trusted his part-ner Their partnership was 0 successfulthat you can scarcely think of one manwithout the other
Musical composers arent the onlyones who form uccessful partnership mntodays manufacturing world partner-ships arealmo t a necessity Originalequipment manefacturers have competi-Lion not only from other manufacturersof similarequipment but 3110 from man-ufacturers of the components that go intotheitrequipment and the service pro-viders who process some of those com-ponems along the way
Ron Davi of Caterpillar Tnc madethis point at the recent annual meetingof the American Gear ManufacturersAs ociation Davis works in Caterpil-lars busine s administration divisionwhich help decide when to manufac-ture components in-house and when tooutsource them
Caterpmarequipment require abroad range of gear products includingtransmission shafts straight and spiralbevel gears planet gears sun gears andfinal drive ring gears They use largequantities of both machined and powdermetal gears
But Caterpillar cant hope to staycompetitive by rnanufaciuri ng all of itscomponents when other companies spe-cialize in manufacturing some of thosecomponents Davis says
The challenge is to decide whichcomponents and manufacturing process-es give Caterpillar the greatest competi-tive advantage when manufactured in-house and which give them the greatestcompetitive advantage when outsourcedOf course the ccmpanyexamines factorssuch as cost quality and customer satis-faction when considering competitiveadvantage Another factor is whetherCaterpillar has special expertise in man-ufacturing a particular component Thecompany also examines various risk cri-teria whether a part requires proprietarytechnology whether its an aftermarket-critical component or whether its time-to-market is critical
Those components that give them thegreatest competitive advantage whenmanufactured in-house are part of Cat-erpillars core competency Outsourcingthose components could lower the quali-Iy of the end-product make it moreexpensive or otherwise worsen the com-panys position in the marketplaceComponent that are not a part ofCaterpillars core competency might bebetter manufactured by others special-ists who can lower the costs improve thequality or both Outsourcing those nOI1-
core components also affords Caterpillarthe opportunity to devote its ownresources to improving those processesand products that are part of its covecompetency
Many of Caterpillars less criticalhigh-volume components such as enginegears are generally outsourced Criticalcomponents such as large transmissionsor filial drive gears are generally manu-factured in-house Medium-duty compo-nents such as small axles and small
transmissions are mixed between in-house manufacturing and outsourcing
Some of the ontsoureed gears aremanufactured by Avon Gear Co a divi-sion of Okubo Gear Co Ltd inRochester Hill MI At the AGMA meet-ing ] had the chance to talk with AvonGears president Aaron Remsing
According to Rem ing there was alime not long ago when Avon Gear hada near-death experience Business wasdown the company had just moved intoa new expensive building and thefuture wa uncertain Avon Gear had todo some soul-searching about its busi-ness Management wa forced to thinkabout the companys capabilities andreinvent the way that it obtained newbusiness Rernsing says The answer layin examining the companys own corecompetencies
Avon Gear knew it had the technicalexpertise equipment and experience tomanufacture certain sizes Iypes andquantities of gears of excellcru qualityand at competitive prices Instead ofwaiting for orders to come in Remsing
wlO powertransmuoncom bull f1OfgllarrechnoJogycom bull GEAR TECHNOLOGY 11IYfJUNE 2001 7
PUBLISHERS PAGEsays the company began approachingthose customers who could best takeadvantage of Avon Gears core compe-tencies One of those companies wasCaterpillar
By making a commitment to special-ize in a certain type of gear for a certainmarket segment Avon Gear was able tocapture Caterpillars business That busi-ness in tum allowed the company anopportunity to invest in new equipment
and training to provide even greater com-petitive advantage
Today according to Davis AvonGear is one of the most important sup-pliers for Caterpillars transmissionbusiness unit Working together thecompanies are able to provide theworld-class manufacturing quality andpricing on gear components that helpkeep Caterpillars equipment competi-tive in the world market Furiliermore
bullIng
Remove nicks buns hest treat scaleand Improve gear tooth surface
Onr 30 J8IlI ago morllaar1lalll developed the gelDbilihlmidlddDglllllllilnnJllOC8llPat JOU trust In tbe people who Invented the process
MAatlNE FEATURESINCLUDEbull Fully automated systemsbull High speed machinesbull Patented Gerac
Oscillation Systembull Automatic spherical
position Ingbull Trl-varlable die designbull Horizontal or vertical axis
machinesbull Variety of gear types
For additional information on IhHuBurnishingandor Functional flfiu
Inectionvisit our website ottIVIIVw ilWgearscom
ITP1tl HeartlandWorkilll9 components 01 theHorizontal Bumisher
1205 36th Avenue WestAlexandria MN 56308 USA
Ph (320) 762-8782Fax (320) 782-5280
E-mail ItwgeaISOrea-alpoom
8 MAYJU NE 2001 GEAFi TECHNOLOGYmiddot www9Ilartllchnolo9ycom bull wWWpowllrtransmissioncom
~c~l(JoldsteinPublisher amp Editor-in-Chief
the processes machines and expertisedeveloped by Avon Gear have given thecompany the ability to sell gears ofworld-class quality and price to othercustomers with similar needs
In fact Davis saysthe partnershipbetween these two companies has devel-oped into one of mutua] trust and plan-ning Like most successful partnershipsits now in the best interest of each partythat the other doesnt fail
Like Caterpillar and Avon Gear eachof our own companies has core compe-tencies-things that are central to ourbusiness which years of working in cer-tain areas allow us to do better than othercompanies without the same focusFinding those things concentrating onthem and expanding on them can helpmake us more successful
Not finding and developing your corecompetency can have the opposite effectIts true that some companies will bemore focused than others But even themost generalist of companies has corecompetencies For example a general-purpose gear job shop with a broad rangeof equipment and tooling might not seemto have a specific niche Neverthelessthat same company might specialize infast turnaround design assistance orextremely high quality each of whichcould be developed for greater competi-tive advantage in certain marketplaces
You can learn more about your corecompetencies by choice or by necessityIf you do so by choice perhaps you II beable to make intelligent decisions aboutyour companys operations as Caterpil-lar did However if you wait you may beforced to learn about your core compe-tencies the hard way Perhaps youll beable to act quickly enough to save yourcompany as Avon Gear did But thenagain
For 96 years the Bodine name has symbollized quality in power transmissionand motlon control IBodine EIectric Company pioneered the concept ot fracticnalhorsepower motors with integrall gear reducers We calrefully guard our reputationfor producing the quietest smoothest Iiongest-life products in the industry
Now you can tnccrporate those same higlhstandards of qualityrellabtlltyand on-time deillivelry iinto your products that require filneand medium pitch open gears from hundreds to hundreds oftLo - - - ~ -d -nousancs
Bodine Gear Manufacturing employs state-of-the-art eNG gearmanufactuning and inspection technology with in-depthengineening support to service your most demandinQappucattons For skived gears we can be your most competitiivecompetent source
To learn more about Bodiine Gear Manufacturing and get your Free Bodiine Gears capvisit ww-wBodineGearscomFreeCaphtm or call toll flree 877-4GEARS9
Sales Representative inquiries welcome
CIRetIE 109
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Quieter GearsEngineered Metals
Theres only one way to ensure thatthe gears you produce win always deliversuperior and quiet performance Make suretheyre bred from quaUty stock
Dura-Bars continuous-cast gray and ductileiron performs like free-machining steel with anImportantadded bonus - quieter operation
Like steel Dura-Bar can he austemperedthrough-hardened flame-hardened or induction-hardened for added wear resistance Butthesuperior noise and vibration damping characteristicsof Dura-Bar make for quieter runninggears AndDura-Bar is 10Ughter than steel
Dura-Bar round bars are avatlable In diametersnnging from 58~ to 20 and lengths of 6-20 So youwont need to make major changes in your machining equipment And our extensive mventory means Dura-Bar is available now - when you need U
Wben Its quaUtymaterial quiet performance and quick deUverythatcount look to continuous-cast Dura-Bar for your gear production needs
DURA~BARreg 1-S00BAR-MILL (227-6455) - 815-338-7800 -Fax 815-338middot15492100 West Lake Shore Drive Woodstock H-60098-7497Web Site wwwdiutamiddotbalcom bull E-mail salesdura-barcQmContinuous Cast Iron Bar Stock
Contact us for the latest dat8iOD geuDouemiddot
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REVOLUTIONS -- _
Hlarmonic ConceptsJazz lp
Planetary DesiglnIn the world of planetary
servo drives precision iseverything Advertisementsabound fOJ ervo gear driveswith extremely low or evenzere backlash With that typeof drive in high demand man-ufacturers have done every-thing they can to tighten theirdesigns-thmugh more exact-ing tolerances tighter assem-bly and better materials
Instead of tightening onemanufacturer of planetaryservo drives has tried loosen-
mg in order [0 provide the lowbacklash that manufacturers ofrobotics and other precise posi-
tioning equipment requireThat loosening bas nothing
te do with the manufacturingtolerances or assembly Pre-cision manufacturing is stillrequired Ithas to do with atype of flexibility borrowedfrom a related technologyharmonic drive gearing
Harmonic drive gearinghas long been known for itslow backlash high precisionand compact design Har-monic drive systems use a cir-cular spline a flex spline and
Cut-away view of the HPG gear drive from HIl Systems
me HPG drive includes II 11111 lIear 10 cantro bacldash(defoRnltion 8xallllerated for mustrative purposes
wavegenera~or to createextremely high ratios in a sin-gle reduction One of theadvantages of the harmonicdrive system is that the flexspline deforms as it rotates tokeep its teeth fully loadedagainst the circular spline alaU times
Engineers at HD Systems ofHauppauge NY haveliguredout how to apply the deforma-tion concept of harmonic drivesystems to planetary gears aswell Instead of a flexible imlerspline bull the HPG harmonicplanetary gearheads use aflexible outer ring gear to pre-load the gearset
The flexible outer ringgear of the HPG gearheadcreates a continually adju l-ing backlash compensationmethod The ring gear is thin-ner in the radial directionthan a typical ring gear Thismakes it radjaUy flexible yettorsionally stiff says HDSystems marketing managerBrian St Denis As normal
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gear wear occurs any in-crease in space between the
jteeth is immediately compen- Isated by the preload in the ring gear The concept is as if Ithe ring gear is a spring in the Iradial direction
The system employed byHD Systems has a huge advan-tage over those commonlyemployed by other maaufac-turers says St Denis Thebackla h of the HPG drivewont deteriorate over time
One method commonlyemployed toprovide low orzero backlash ill planetarygear systems is to create atight fit between all of thegears However this methodis subject to gear tooth wearand over the life of the gear-box the backl3sll can increasesignificantly
Another method is to usepreloaded bevel gears as panof the mechanism Shimsforce the bevel gears togetheraxially which forces a raclialpreload in the planetary gearsBacklash in this type of sys-tem also increases over timebecause of gear tooth wear
Because of the flexibledefermation of the planetaryring gear the HPG gearheadautomaucally compensatesfor gear tooth wear 81 Dellisays This helps ensure con-sistent backlash throughoutthe rated life of the gearbox
The H~ Series planetarygearheads have standardbacklash of less than 3 arc-minutes and they can beordered with 1 arc-minute ofbacklash as an option Theyare available in ratios from51 to 331
Cirele3mwwwpow9rrsnsmlssloncom bull wwwge8rtechnQJoycom bull GEAR TECHNOLOGYmiddotmiddot MAYJUNE 2001
MicmgearsFor Use In Tlhe
IHuman MachineIn a Hungarian lab using a
microscopes laser research-ers are creating gears androtors thinner than a humanhair ADd willie hair growsout of the body the re-searchers want to put theirgears and rotors into the bodyin microsoopic machines forconducting experiments
Its like the movie innerSpace wilh Dennis Quaidsays researcher p~ OrmosThe machines could be builtso small that they would fitinto blood vessels for analyz-ing blood
To create the gears androtors Onnos uses hardenedliquid photopolymer Butunlike the micropans and their
pos ible lise the material isntnearly as exotic
Dentists use it a letann os says The material isthe same as whats II ed fortooth fillings hardened withultraviolet light
Ormes developed the tech-nique with Fewr Galajda in alittle more than a year--Just now weare perfectingit Ormes acids that hed likero use the technique in lessthan a year to build everaltypes of machine
Willi a doctorate ill phys-ics Ormos belongs to theHungarian Academy of Sci-ences and works at itsBiological Research Centrelocated in Szeged Ormos isdirector of the centres Insti-tnte of Biophy it Galajda istis doctoral snrdent
We study thephysics of
Created undBr II microscope threll rotan appear in front of the Dak-likeIJIIJ1Jc lif bullbullbull II 110mB n bairLivingsystems Ormes says Ormos and Galajdas gearsHe acids lliat theres a strong and rotors could be usedjndrive ill biology toward minia- that study as parts in micro-turizing which has a lot of scopic biochemical device promise in it The micromachines would be
bull accuracybull reliabilitybull maintolinCibilitybull Hexibilily performancebull and life cyde eest
AI Klingelnberg the point ofprecision is 10 help you controlyour gear manufocturing pro-cess and improve gearqudlitywith measuring systems thaIare benchmarks for
Klingelnberg measuringtechnology contaeLiebherr Gear Technology Co1465 Woodland DriveSaline MI4B 176-1259
_------------REVOLUTIONS------------_used ro investigate living sys-terns at a cellular level per-mitting the movement of indi-vidual ceIls-even individuallarge molecules Ormos says~ts a very precise tool thatcan be used in biology
With such machines scien-tists could introduce chemi-cals into cells manipulatetheir reactions and maintainthose cells environmentspumping different solutions todifferent regions They couldmeasure cell properties toselect certaia cells create achannel for transporting thosecells and transport the cellsindividually They could alsoremove compounds fromcells even destroy cells
The gears and rotors diam-eters can be as small as twomicrons A human hales diam-eter is about 100 microns At
two microns the parts canweigh as little as ]()LO grams
Ormos and GaIajda maketheir microparts by placingliquid photopolymer under amicroscope then moving acomputer-controlled laser fo-cus into the microscopeWhereverthe focus movesthe liquid becomes hardenedIf it moves in a gear shape thefocus makes a hardened gear
We can create a three-dimensionalobject that is ascomplicated as we wantOrmes says
DUI theres a wri nkle inthe technology that needs tobe ironed out
The micro gears are rotatedby the microrotors The micro-rotors are rotated by light
Its not easy to introducelight into the blood vesselsOmms says
But he adds there may be asolution to that problemOrmos explains that themachines in the body could bepowered by tightlfit wereintroduced effectively-via athin optic fiber for example
In similar research SandiaNational Laboratories in NewMexico has used chemicalmiddotelching to create microgearsand experimental micro-engines electric motors no
1 larger than a grain of sandOrmos started his research
j to understand how light causesI different trapped particles toj rotate But he later realizedi such light-induced rotationi could have useful applicationsI
1 It was not really the areaI
1 in which we were deliberately
II
moving he saysOnnos is unsure about the
techniques future-Whether
this can be commercialized ornot isnt clear Still he andOalajda are testing resins todecide which works best forcreating their gears and rotors
I think the possibilities arereally uolimited Ormes saysAnything that can be donewith larger machines can bedone with smaller ones too
Cirde302
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Phone + 1-734-429-7225Fax 1-734-429-2294wwwpointofprecisioncominfopointofprecisioncom
bull 1INDUSTRV NEWS _
Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
S86 HilliardStreet RO Box 1898 Manchester CT06045-1898 USATelephone 86() 1649-0000 bull Fax 860 645-629g
Home Page httpwwwpurdytransmissionscomf-Mail salespurrlytransmissonsfOffl
Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
Fifty years or VARI-ROLL applications providebull Production Composite Inspectionbull Custom Design amp Build Part Gear Mounting Fixturesbull Standard Mounting Fixtures - Spurs Helicals Pinion Shafts
Worms Throated Worms Bevels Internals
When coupled with the VARI-PC Composite Gear AnalysisSystem will providebull Reduced Inspection Cost Improved Accuracy Historical Record Keepingbull Serialization of Partsbull Interface to SPC programsExperience the difference See why customers worldwide havechosen the VARI-ROLUVARImiddotPC For further informationplease contact us
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United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
CIRCLE 1Ji
ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
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16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
S- Amcricllinc
Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
far __ illfonnalion eIIouI bull prIIIiucI DIIHrYiCJ JdHftIMd Ii hil iUIIII IIf 6_rfthohlfr I~-IM appropriate IIIUIIIber IIIIM lIIdr IInpg_ Callli MIlput ilia clrd in Ihe lIIIiI
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IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
AIW Sy5lcmsAero Gar [nc
AGMAAja M~ Corp
AmmCllll MeIlll T~1l Co
Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
1_1 I)CiuIG~tIJ TlaquohnoIDV
Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
TIle Gleason WollksHolroyd
lndex Technologies lee
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lnsco Corplnterstate Tool CorpTW H~ltIlandKim ~lnberg S(IIme GmbHKprOf AlneriQ LLCKoro Sluupening ServiceKrei~r~hleCoonl Ine
Mew Media loeb amp More
MiCroGCATMidwest Gear amp Tool IncMidWeIgtlGeM Corp
acbil Mrchjning Techno[ogy Co
iagllIll Gear Corp
Nona Gear Failure Semiruur
On-Iine ServIlCS Inc
Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
Profile Engmccnog IncPru-Oew Co locThe Purdy Corp
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steel arborFeather lighthydraulicarbors can bemanufactured wilhrunout as low as2 microns The clampingsleeves are replaceabte Thistoolingl is suitable for measuringtesting balancinggear grindingand other applications
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An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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If you would like more information abouta-tllo Bear CO circle1fUATA Geelllld circ _00 Drive a Gear Ltd clrcl aU-If you would like to respond to this or any other articlein this edition of GeBr Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-6618
A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
T Us YOII Think If you found this article of interest andor usefulplease circle aMIf you did not care for this article circle ~
If you would like more information about Pialllurgh ccirc ~If you would like to respond to this or any other articlein this edition of Gear Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-661 B
WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
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Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
I--+--+--t--~ T1RUE DIMENSION GEAR INmiddotSPEC
Provides actual overballpin measurmenof any helical orgear or splin WiLU t-
the need ofcostlysetting masters
Ga~ Division
d Tool _I
9 ODS ID
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851 OHIO PIKE middotCINCINNATI OHIO 45245 bull (513) 152-6000 bull FAX (513) 75205599
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Learn mare at ShON Central
bull Exhlibiitor Liistbull Booth Descriptions
bull NEW THIS YIEAIR Online Videos
Plan our visit to tile sllow months in advainceat Shaw Central
wwwgeartechnologeJlpocomwpowerrtatlamfsslotlcom WWWg9Iut9chnoloflycom GEAR TECHNOLOGYmiddot MAYIJUNIE 2001 45
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
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powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
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ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
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Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
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HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
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Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
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For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
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bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
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Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Combining over 140 years I)f processmachine and tool experience enables NachiliMachining Technology Co to maintainiindustry leadership by proviiding customerswith the best practices manufatctuningsolutions
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Co CoConcentrating on the CllAdal Components
Co Keep Yow CompanyCompe+i+ive
Rodgers and Hammerstein producedorne of Americas most memorable and
lasting songs in musical theater lyricistOscar Hammerstein IIonce aid of com-poser Richard Rodgers I hand him alyric and get out of his way Hammer-stein knew what Rodgers was good atand vice versa and each trusted his part-ner Their partnership was 0 successfulthat you can scarcely think of one manwithout the other
Musical composers arent the onlyones who form uccessful partnership mntodays manufacturing world partner-ships arealmo t a necessity Originalequipment manefacturers have competi-Lion not only from other manufacturersof similarequipment but 3110 from man-ufacturers of the components that go intotheitrequipment and the service pro-viders who process some of those com-ponems along the way
Ron Davi of Caterpillar Tnc madethis point at the recent annual meetingof the American Gear ManufacturersAs ociation Davis works in Caterpil-lars busine s administration divisionwhich help decide when to manufac-ture components in-house and when tooutsource them
Caterpmarequipment require abroad range of gear products includingtransmission shafts straight and spiralbevel gears planet gears sun gears andfinal drive ring gears They use largequantities of both machined and powdermetal gears
But Caterpillar cant hope to staycompetitive by rnanufaciuri ng all of itscomponents when other companies spe-cialize in manufacturing some of thosecomponents Davis says
The challenge is to decide whichcomponents and manufacturing process-es give Caterpillar the greatest competi-tive advantage when manufactured in-house and which give them the greatestcompetitive advantage when outsourcedOf course the ccmpanyexamines factorssuch as cost quality and customer satis-faction when considering competitiveadvantage Another factor is whetherCaterpillar has special expertise in man-ufacturing a particular component Thecompany also examines various risk cri-teria whether a part requires proprietarytechnology whether its an aftermarket-critical component or whether its time-to-market is critical
Those components that give them thegreatest competitive advantage whenmanufactured in-house are part of Cat-erpillars core competency Outsourcingthose components could lower the quali-Iy of the end-product make it moreexpensive or otherwise worsen the com-panys position in the marketplaceComponent that are not a part ofCaterpillars core competency might bebetter manufactured by others special-ists who can lower the costs improve thequality or both Outsourcing those nOI1-
core components also affords Caterpillarthe opportunity to devote its ownresources to improving those processesand products that are part of its covecompetency
Many of Caterpillars less criticalhigh-volume components such as enginegears are generally outsourced Criticalcomponents such as large transmissionsor filial drive gears are generally manu-factured in-house Medium-duty compo-nents such as small axles and small
transmissions are mixed between in-house manufacturing and outsourcing
Some of the ontsoureed gears aremanufactured by Avon Gear Co a divi-sion of Okubo Gear Co Ltd inRochester Hill MI At the AGMA meet-ing ] had the chance to talk with AvonGears president Aaron Remsing
According to Rem ing there was alime not long ago when Avon Gear hada near-death experience Business wasdown the company had just moved intoa new expensive building and thefuture wa uncertain Avon Gear had todo some soul-searching about its busi-ness Management wa forced to thinkabout the companys capabilities andreinvent the way that it obtained newbusiness Rernsing says The answer layin examining the companys own corecompetencies
Avon Gear knew it had the technicalexpertise equipment and experience tomanufacture certain sizes Iypes andquantities of gears of excellcru qualityand at competitive prices Instead ofwaiting for orders to come in Remsing
wlO powertransmuoncom bull f1OfgllarrechnoJogycom bull GEAR TECHNOLOGY 11IYfJUNE 2001 7
PUBLISHERS PAGEsays the company began approachingthose customers who could best takeadvantage of Avon Gears core compe-tencies One of those companies wasCaterpillar
By making a commitment to special-ize in a certain type of gear for a certainmarket segment Avon Gear was able tocapture Caterpillars business That busi-ness in tum allowed the company anopportunity to invest in new equipment
and training to provide even greater com-petitive advantage
Today according to Davis AvonGear is one of the most important sup-pliers for Caterpillars transmissionbusiness unit Working together thecompanies are able to provide theworld-class manufacturing quality andpricing on gear components that helpkeep Caterpillars equipment competi-tive in the world market Furiliermore
bullIng
Remove nicks buns hest treat scaleand Improve gear tooth surface
Onr 30 J8IlI ago morllaar1lalll developed the gelDbilihlmidlddDglllllllilnnJllOC8llPat JOU trust In tbe people who Invented the process
MAatlNE FEATURESINCLUDEbull Fully automated systemsbull High speed machinesbull Patented Gerac
Oscillation Systembull Automatic spherical
position Ingbull Trl-varlable die designbull Horizontal or vertical axis
machinesbull Variety of gear types
For additional information on IhHuBurnishingandor Functional flfiu
Inectionvisit our website ottIVIIVw ilWgearscom
ITP1tl HeartlandWorkilll9 components 01 theHorizontal Bumisher
1205 36th Avenue WestAlexandria MN 56308 USA
Ph (320) 762-8782Fax (320) 782-5280
E-mail ItwgeaISOrea-alpoom
8 MAYJU NE 2001 GEAFi TECHNOLOGYmiddot www9Ilartllchnolo9ycom bull wWWpowllrtransmissioncom
~c~l(JoldsteinPublisher amp Editor-in-Chief
the processes machines and expertisedeveloped by Avon Gear have given thecompany the ability to sell gears ofworld-class quality and price to othercustomers with similar needs
In fact Davis saysthe partnershipbetween these two companies has devel-oped into one of mutua] trust and plan-ning Like most successful partnershipsits now in the best interest of each partythat the other doesnt fail
Like Caterpillar and Avon Gear eachof our own companies has core compe-tencies-things that are central to ourbusiness which years of working in cer-tain areas allow us to do better than othercompanies without the same focusFinding those things concentrating onthem and expanding on them can helpmake us more successful
Not finding and developing your corecompetency can have the opposite effectIts true that some companies will bemore focused than others But even themost generalist of companies has corecompetencies For example a general-purpose gear job shop with a broad rangeof equipment and tooling might not seemto have a specific niche Neverthelessthat same company might specialize infast turnaround design assistance orextremely high quality each of whichcould be developed for greater competi-tive advantage in certain marketplaces
You can learn more about your corecompetencies by choice or by necessityIf you do so by choice perhaps you II beable to make intelligent decisions aboutyour companys operations as Caterpil-lar did However if you wait you may beforced to learn about your core compe-tencies the hard way Perhaps youll beable to act quickly enough to save yourcompany as Avon Gear did But thenagain
For 96 years the Bodine name has symbollized quality in power transmissionand motlon control IBodine EIectric Company pioneered the concept ot fracticnalhorsepower motors with integrall gear reducers We calrefully guard our reputationfor producing the quietest smoothest Iiongest-life products in the industry
Now you can tnccrporate those same higlhstandards of qualityrellabtlltyand on-time deillivelry iinto your products that require filneand medium pitch open gears from hundreds to hundreds oftLo - - - ~ -d -nousancs
Bodine Gear Manufacturing employs state-of-the-art eNG gearmanufactuning and inspection technology with in-depthengineening support to service your most demandinQappucattons For skived gears we can be your most competitiivecompetent source
To learn more about Bodiine Gear Manufacturing and get your Free Bodiine Gears capvisit ww-wBodineGearscomFreeCaphtm or call toll flree 877-4GEARS9
Sales Representative inquiries welcome
CIRetIE 109
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Quieter GearsEngineered Metals
Theres only one way to ensure thatthe gears you produce win always deliversuperior and quiet performance Make suretheyre bred from quaUty stock
Dura-Bars continuous-cast gray and ductileiron performs like free-machining steel with anImportantadded bonus - quieter operation
Like steel Dura-Bar can he austemperedthrough-hardened flame-hardened or induction-hardened for added wear resistance Butthesuperior noise and vibration damping characteristicsof Dura-Bar make for quieter runninggears AndDura-Bar is 10Ughter than steel
Dura-Bar round bars are avatlable In diametersnnging from 58~ to 20 and lengths of 6-20 So youwont need to make major changes in your machining equipment And our extensive mventory means Dura-Bar is available now - when you need U
Wben Its quaUtymaterial quiet performance and quick deUverythatcount look to continuous-cast Dura-Bar for your gear production needs
DURA~BARreg 1-S00BAR-MILL (227-6455) - 815-338-7800 -Fax 815-338middot15492100 West Lake Shore Drive Woodstock H-60098-7497Web Site wwwdiutamiddotbalcom bull E-mail salesdura-barcQmContinuous Cast Iron Bar Stock
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REVOLUTIONS -- _
Hlarmonic ConceptsJazz lp
Planetary DesiglnIn the world of planetary
servo drives precision iseverything Advertisementsabound fOJ ervo gear driveswith extremely low or evenzere backlash With that typeof drive in high demand man-ufacturers have done every-thing they can to tighten theirdesigns-thmugh more exact-ing tolerances tighter assem-bly and better materials
Instead of tightening onemanufacturer of planetaryservo drives has tried loosen-
mg in order [0 provide the lowbacklash that manufacturers ofrobotics and other precise posi-
tioning equipment requireThat loosening bas nothing
te do with the manufacturingtolerances or assembly Pre-cision manufacturing is stillrequired Ithas to do with atype of flexibility borrowedfrom a related technologyharmonic drive gearing
Harmonic drive gearinghas long been known for itslow backlash high precisionand compact design Har-monic drive systems use a cir-cular spline a flex spline and
Cut-away view of the HPG gear drive from HIl Systems
me HPG drive includes II 11111 lIear 10 cantro bacldash(defoRnltion 8xallllerated for mustrative purposes
wavegenera~or to createextremely high ratios in a sin-gle reduction One of theadvantages of the harmonicdrive system is that the flexspline deforms as it rotates tokeep its teeth fully loadedagainst the circular spline alaU times
Engineers at HD Systems ofHauppauge NY haveliguredout how to apply the deforma-tion concept of harmonic drivesystems to planetary gears aswell Instead of a flexible imlerspline bull the HPG harmonicplanetary gearheads use aflexible outer ring gear to pre-load the gearset
The flexible outer ringgear of the HPG gearheadcreates a continually adju l-ing backlash compensationmethod The ring gear is thin-ner in the radial directionthan a typical ring gear Thismakes it radjaUy flexible yettorsionally stiff says HDSystems marketing managerBrian St Denis As normal
Wecome to Revolu-
Iions th column tIItbrings you the Illtest
most up-to-dBtl ndeasY-Io-read informll-
tion bout the people
nd technology of thegell industry Revolu-
Uons welcomes OUsubmissions PleBSe
sefid them to Gear
Technologv PO Box1426 flk Grore VillageIt 60009 or fx (HI)
431-6618 If youd like
more infomllltion sbout
flY of the articles that
appellrpiliS cirelli theappropiate number on
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gear wear occurs any in-crease in space between the
jteeth is immediately compen- Isated by the preload in the ring gear The concept is as if Ithe ring gear is a spring in the Iradial direction
The system employed byHD Systems has a huge advan-tage over those commonlyemployed by other maaufac-turers says St Denis Thebackla h of the HPG drivewont deteriorate over time
One method commonlyemployed toprovide low orzero backlash ill planetarygear systems is to create atight fit between all of thegears However this methodis subject to gear tooth wearand over the life of the gear-box the backl3sll can increasesignificantly
Another method is to usepreloaded bevel gears as panof the mechanism Shimsforce the bevel gears togetheraxially which forces a raclialpreload in the planetary gearsBacklash in this type of sys-tem also increases over timebecause of gear tooth wear
Because of the flexibledefermation of the planetaryring gear the HPG gearheadautomaucally compensatesfor gear tooth wear 81 Dellisays This helps ensure con-sistent backlash throughoutthe rated life of the gearbox
The H~ Series planetarygearheads have standardbacklash of less than 3 arc-minutes and they can beordered with 1 arc-minute ofbacklash as an option Theyare available in ratios from51 to 331
Cirele3mwwwpow9rrsnsmlssloncom bull wwwge8rtechnQJoycom bull GEAR TECHNOLOGYmiddotmiddot MAYJUNE 2001
MicmgearsFor Use In Tlhe
IHuman MachineIn a Hungarian lab using a
microscopes laser research-ers are creating gears androtors thinner than a humanhair ADd willie hair growsout of the body the re-searchers want to put theirgears and rotors into the bodyin microsoopic machines forconducting experiments
Its like the movie innerSpace wilh Dennis Quaidsays researcher p~ OrmosThe machines could be builtso small that they would fitinto blood vessels for analyz-ing blood
To create the gears androtors Onnos uses hardenedliquid photopolymer Butunlike the micropans and their
pos ible lise the material isntnearly as exotic
Dentists use it a letann os says The material isthe same as whats II ed fortooth fillings hardened withultraviolet light
Ormes developed the tech-nique with Fewr Galajda in alittle more than a year--Just now weare perfectingit Ormes acids that hed likero use the technique in lessthan a year to build everaltypes of machine
Willi a doctorate ill phys-ics Ormos belongs to theHungarian Academy of Sci-ences and works at itsBiological Research Centrelocated in Szeged Ormos isdirector of the centres Insti-tnte of Biophy it Galajda istis doctoral snrdent
We study thephysics of
Created undBr II microscope threll rotan appear in front of the Dak-likeIJIIJ1Jc lif bullbullbull II 110mB n bairLivingsystems Ormes says Ormos and Galajdas gearsHe acids lliat theres a strong and rotors could be usedjndrive ill biology toward minia- that study as parts in micro-turizing which has a lot of scopic biochemical device promise in it The micromachines would be
bull accuracybull reliabilitybull maintolinCibilitybull Hexibilily performancebull and life cyde eest
AI Klingelnberg the point ofprecision is 10 help you controlyour gear manufocturing pro-cess and improve gearqudlitywith measuring systems thaIare benchmarks for
Klingelnberg measuringtechnology contaeLiebherr Gear Technology Co1465 Woodland DriveSaline MI4B 176-1259
_------------REVOLUTIONS------------_used ro investigate living sys-terns at a cellular level per-mitting the movement of indi-vidual ceIls-even individuallarge molecules Ormos says~ts a very precise tool thatcan be used in biology
With such machines scien-tists could introduce chemi-cals into cells manipulatetheir reactions and maintainthose cells environmentspumping different solutions todifferent regions They couldmeasure cell properties toselect certaia cells create achannel for transporting thosecells and transport the cellsindividually They could alsoremove compounds fromcells even destroy cells
The gears and rotors diam-eters can be as small as twomicrons A human hales diam-eter is about 100 microns At
two microns the parts canweigh as little as ]()LO grams
Ormos and GaIajda maketheir microparts by placingliquid photopolymer under amicroscope then moving acomputer-controlled laser fo-cus into the microscopeWhereverthe focus movesthe liquid becomes hardenedIf it moves in a gear shape thefocus makes a hardened gear
We can create a three-dimensionalobject that is ascomplicated as we wantOrmes says
DUI theres a wri nkle inthe technology that needs tobe ironed out
The micro gears are rotatedby the microrotors The micro-rotors are rotated by light
Its not easy to introducelight into the blood vesselsOmms says
But he adds there may be asolution to that problemOrmos explains that themachines in the body could bepowered by tightlfit wereintroduced effectively-via athin optic fiber for example
In similar research SandiaNational Laboratories in NewMexico has used chemicalmiddotelching to create microgearsand experimental micro-engines electric motors no
1 larger than a grain of sandOrmos started his research
j to understand how light causesI different trapped particles toj rotate But he later realizedi such light-induced rotationi could have useful applicationsI
1 It was not really the areaI
1 in which we were deliberately
II
moving he saysOnnos is unsure about the
techniques future-Whether
this can be commercialized ornot isnt clear Still he andOalajda are testing resins todecide which works best forcreating their gears and rotors
I think the possibilities arereally uolimited Ormes saysAnything that can be donewith larger machines can bedone with smaller ones too
Cirde302
Tbullbull V
If you found tIriI IfticfI ofinterest andor UIefuI
~
l1~~
Phone + 1-734-429-7225Fax 1-734-429-2294wwwpointofprecisioncominfopointofprecisioncom
bull 1INDUSTRV NEWS _
Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
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Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
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Worms Throated Worms Bevels Internals
When coupled with the VARI-PC Composite Gear AnalysisSystem will providebull Reduced Inspection Cost Improved Accuracy Historical Record Keepingbull Serialization of Partsbull Interface to SPC programsExperience the difference See why customers worldwide havechosen the VARI-ROLUVARImiddotPC For further informationplease contact us
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United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
CIRCLE 1Ji
ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
Will YoI TIIiIk bullbullIf you found 1his column of inbaIt lIIdIoruseful pIe
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16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
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Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
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IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
AIW Sy5lcmsAero Gar [nc
AGMAAja M~ Corp
AmmCllll MeIlll T~1l Co
Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
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Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
TIle Gleason WollksHolroyd
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lnsco Corplnterstate Tool CorpTW H~ltIlandKim ~lnberg S(IIme GmbHKprOf AlneriQ LLCKoro Sluupening ServiceKrei~r~hleCoonl Ine
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MiCroGCATMidwest Gear amp Tool IncMidWeIgtlGeM Corp
acbil Mrchjning Techno[ogy Co
iagllIll Gear Corp
Nona Gear Failure Semiruur
On-Iine ServIlCS Inc
Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
Profile Engmccnog IncPru-Oew Co locThe Purdy Corp
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GROUND GEARS- TeD or ren lhousandFor small to medium Quantities of spurs or helicals that have tomeet close-tolerance AGMA or DIN specs our Relshauer grindersand MampM gear analysis systems arelhe perfect combination
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ORPORATION
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TooHnk Engineeringoffers hydraulic arbors
made of a lightmetal alloy that
weigh up to70 less thana comparable
steel arborFeather lighthydraulicarbors can bemanufactured wilhrunout as low as2 microns The clampingsleeves are replaceabte Thistoolingl is suitable for measuringtesting balancinggear grindingand other applications
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An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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If you would like more information abouta-tllo Bear CO circle1fUATA Geelllld circ _00 Drive a Gear Ltd clrcl aU-If you would like to respond to this or any other articlein this edition of GeBr Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-6618
A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
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AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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Spiral amp Straight BevellGear ManufBctulngCommercial to aircraft quaiity gearing
Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
MIIlWist GEARamp TOIl IINC
ICONTACTCRAIGi D RIISS(B10) 754middot8923
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
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Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
If you found this article of interest andoruseful pI sa circle
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
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Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
-
PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
_-----------IIPUBUSHERS IPAGiE 1 _
Co CoConcentrating on the CllAdal Components
Co Keep Yow CompanyCompe+i+ive
Rodgers and Hammerstein producedorne of Americas most memorable and
lasting songs in musical theater lyricistOscar Hammerstein IIonce aid of com-poser Richard Rodgers I hand him alyric and get out of his way Hammer-stein knew what Rodgers was good atand vice versa and each trusted his part-ner Their partnership was 0 successfulthat you can scarcely think of one manwithout the other
Musical composers arent the onlyones who form uccessful partnership mntodays manufacturing world partner-ships arealmo t a necessity Originalequipment manefacturers have competi-Lion not only from other manufacturersof similarequipment but 3110 from man-ufacturers of the components that go intotheitrequipment and the service pro-viders who process some of those com-ponems along the way
Ron Davi of Caterpillar Tnc madethis point at the recent annual meetingof the American Gear ManufacturersAs ociation Davis works in Caterpil-lars busine s administration divisionwhich help decide when to manufac-ture components in-house and when tooutsource them
Caterpmarequipment require abroad range of gear products includingtransmission shafts straight and spiralbevel gears planet gears sun gears andfinal drive ring gears They use largequantities of both machined and powdermetal gears
But Caterpillar cant hope to staycompetitive by rnanufaciuri ng all of itscomponents when other companies spe-cialize in manufacturing some of thosecomponents Davis says
The challenge is to decide whichcomponents and manufacturing process-es give Caterpillar the greatest competi-tive advantage when manufactured in-house and which give them the greatestcompetitive advantage when outsourcedOf course the ccmpanyexamines factorssuch as cost quality and customer satis-faction when considering competitiveadvantage Another factor is whetherCaterpillar has special expertise in man-ufacturing a particular component Thecompany also examines various risk cri-teria whether a part requires proprietarytechnology whether its an aftermarket-critical component or whether its time-to-market is critical
Those components that give them thegreatest competitive advantage whenmanufactured in-house are part of Cat-erpillars core competency Outsourcingthose components could lower the quali-Iy of the end-product make it moreexpensive or otherwise worsen the com-panys position in the marketplaceComponent that are not a part ofCaterpillars core competency might bebetter manufactured by others special-ists who can lower the costs improve thequality or both Outsourcing those nOI1-
core components also affords Caterpillarthe opportunity to devote its ownresources to improving those processesand products that are part of its covecompetency
Many of Caterpillars less criticalhigh-volume components such as enginegears are generally outsourced Criticalcomponents such as large transmissionsor filial drive gears are generally manu-factured in-house Medium-duty compo-nents such as small axles and small
transmissions are mixed between in-house manufacturing and outsourcing
Some of the ontsoureed gears aremanufactured by Avon Gear Co a divi-sion of Okubo Gear Co Ltd inRochester Hill MI At the AGMA meet-ing ] had the chance to talk with AvonGears president Aaron Remsing
According to Rem ing there was alime not long ago when Avon Gear hada near-death experience Business wasdown the company had just moved intoa new expensive building and thefuture wa uncertain Avon Gear had todo some soul-searching about its busi-ness Management wa forced to thinkabout the companys capabilities andreinvent the way that it obtained newbusiness Rernsing says The answer layin examining the companys own corecompetencies
Avon Gear knew it had the technicalexpertise equipment and experience tomanufacture certain sizes Iypes andquantities of gears of excellcru qualityand at competitive prices Instead ofwaiting for orders to come in Remsing
wlO powertransmuoncom bull f1OfgllarrechnoJogycom bull GEAR TECHNOLOGY 11IYfJUNE 2001 7
PUBLISHERS PAGEsays the company began approachingthose customers who could best takeadvantage of Avon Gears core compe-tencies One of those companies wasCaterpillar
By making a commitment to special-ize in a certain type of gear for a certainmarket segment Avon Gear was able tocapture Caterpillars business That busi-ness in tum allowed the company anopportunity to invest in new equipment
and training to provide even greater com-petitive advantage
Today according to Davis AvonGear is one of the most important sup-pliers for Caterpillars transmissionbusiness unit Working together thecompanies are able to provide theworld-class manufacturing quality andpricing on gear components that helpkeep Caterpillars equipment competi-tive in the world market Furiliermore
bullIng
Remove nicks buns hest treat scaleand Improve gear tooth surface
Onr 30 J8IlI ago morllaar1lalll developed the gelDbilihlmidlddDglllllllilnnJllOC8llPat JOU trust In tbe people who Invented the process
MAatlNE FEATURESINCLUDEbull Fully automated systemsbull High speed machinesbull Patented Gerac
Oscillation Systembull Automatic spherical
position Ingbull Trl-varlable die designbull Horizontal or vertical axis
machinesbull Variety of gear types
For additional information on IhHuBurnishingandor Functional flfiu
Inectionvisit our website ottIVIIVw ilWgearscom
ITP1tl HeartlandWorkilll9 components 01 theHorizontal Bumisher
1205 36th Avenue WestAlexandria MN 56308 USA
Ph (320) 762-8782Fax (320) 782-5280
E-mail ItwgeaISOrea-alpoom
8 MAYJU NE 2001 GEAFi TECHNOLOGYmiddot www9Ilartllchnolo9ycom bull wWWpowllrtransmissioncom
~c~l(JoldsteinPublisher amp Editor-in-Chief
the processes machines and expertisedeveloped by Avon Gear have given thecompany the ability to sell gears ofworld-class quality and price to othercustomers with similar needs
In fact Davis saysthe partnershipbetween these two companies has devel-oped into one of mutua] trust and plan-ning Like most successful partnershipsits now in the best interest of each partythat the other doesnt fail
Like Caterpillar and Avon Gear eachof our own companies has core compe-tencies-things that are central to ourbusiness which years of working in cer-tain areas allow us to do better than othercompanies without the same focusFinding those things concentrating onthem and expanding on them can helpmake us more successful
Not finding and developing your corecompetency can have the opposite effectIts true that some companies will bemore focused than others But even themost generalist of companies has corecompetencies For example a general-purpose gear job shop with a broad rangeof equipment and tooling might not seemto have a specific niche Neverthelessthat same company might specialize infast turnaround design assistance orextremely high quality each of whichcould be developed for greater competi-tive advantage in certain marketplaces
You can learn more about your corecompetencies by choice or by necessityIf you do so by choice perhaps you II beable to make intelligent decisions aboutyour companys operations as Caterpil-lar did However if you wait you may beforced to learn about your core compe-tencies the hard way Perhaps youll beable to act quickly enough to save yourcompany as Avon Gear did But thenagain
For 96 years the Bodine name has symbollized quality in power transmissionand motlon control IBodine EIectric Company pioneered the concept ot fracticnalhorsepower motors with integrall gear reducers We calrefully guard our reputationfor producing the quietest smoothest Iiongest-life products in the industry
Now you can tnccrporate those same higlhstandards of qualityrellabtlltyand on-time deillivelry iinto your products that require filneand medium pitch open gears from hundreds to hundreds oftLo - - - ~ -d -nousancs
Bodine Gear Manufacturing employs state-of-the-art eNG gearmanufactuning and inspection technology with in-depthengineening support to service your most demandinQappucattons For skived gears we can be your most competitiivecompetent source
To learn more about Bodiine Gear Manufacturing and get your Free Bodiine Gears capvisit ww-wBodineGearscomFreeCaphtm or call toll flree 877-4GEARS9
Sales Representative inquiries welcome
CIRetIE 109
~-~ -- - ------------------
Quieter GearsEngineered Metals
Theres only one way to ensure thatthe gears you produce win always deliversuperior and quiet performance Make suretheyre bred from quaUty stock
Dura-Bars continuous-cast gray and ductileiron performs like free-machining steel with anImportantadded bonus - quieter operation
Like steel Dura-Bar can he austemperedthrough-hardened flame-hardened or induction-hardened for added wear resistance Butthesuperior noise and vibration damping characteristicsof Dura-Bar make for quieter runninggears AndDura-Bar is 10Ughter than steel
Dura-Bar round bars are avatlable In diametersnnging from 58~ to 20 and lengths of 6-20 So youwont need to make major changes in your machining equipment And our extensive mventory means Dura-Bar is available now - when you need U
Wben Its quaUtymaterial quiet performance and quick deUverythatcount look to continuous-cast Dura-Bar for your gear production needs
DURA~BARreg 1-S00BAR-MILL (227-6455) - 815-338-7800 -Fax 815-338middot15492100 West Lake Shore Drive Woodstock H-60098-7497Web Site wwwdiutamiddotbalcom bull E-mail salesdura-barcQmContinuous Cast Iron Bar Stock
Contact us for the latest dat8iOD geuDouemiddot
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REVOLUTIONS -- _
Hlarmonic ConceptsJazz lp
Planetary DesiglnIn the world of planetary
servo drives precision iseverything Advertisementsabound fOJ ervo gear driveswith extremely low or evenzere backlash With that typeof drive in high demand man-ufacturers have done every-thing they can to tighten theirdesigns-thmugh more exact-ing tolerances tighter assem-bly and better materials
Instead of tightening onemanufacturer of planetaryservo drives has tried loosen-
mg in order [0 provide the lowbacklash that manufacturers ofrobotics and other precise posi-
tioning equipment requireThat loosening bas nothing
te do with the manufacturingtolerances or assembly Pre-cision manufacturing is stillrequired Ithas to do with atype of flexibility borrowedfrom a related technologyharmonic drive gearing
Harmonic drive gearinghas long been known for itslow backlash high precisionand compact design Har-monic drive systems use a cir-cular spline a flex spline and
Cut-away view of the HPG gear drive from HIl Systems
me HPG drive includes II 11111 lIear 10 cantro bacldash(defoRnltion 8xallllerated for mustrative purposes
wavegenera~or to createextremely high ratios in a sin-gle reduction One of theadvantages of the harmonicdrive system is that the flexspline deforms as it rotates tokeep its teeth fully loadedagainst the circular spline alaU times
Engineers at HD Systems ofHauppauge NY haveliguredout how to apply the deforma-tion concept of harmonic drivesystems to planetary gears aswell Instead of a flexible imlerspline bull the HPG harmonicplanetary gearheads use aflexible outer ring gear to pre-load the gearset
The flexible outer ringgear of the HPG gearheadcreates a continually adju l-ing backlash compensationmethod The ring gear is thin-ner in the radial directionthan a typical ring gear Thismakes it radjaUy flexible yettorsionally stiff says HDSystems marketing managerBrian St Denis As normal
Wecome to Revolu-
Iions th column tIItbrings you the Illtest
most up-to-dBtl ndeasY-Io-read informll-
tion bout the people
nd technology of thegell industry Revolu-
Uons welcomes OUsubmissions PleBSe
sefid them to Gear
Technologv PO Box1426 flk Grore VillageIt 60009 or fx (HI)
431-6618 If youd like
more infomllltion sbout
flY of the articles that
appellrpiliS cirelli theappropiate number on
the Reader Service Card
gear wear occurs any in-crease in space between the
jteeth is immediately compen- Isated by the preload in the ring gear The concept is as if Ithe ring gear is a spring in the Iradial direction
The system employed byHD Systems has a huge advan-tage over those commonlyemployed by other maaufac-turers says St Denis Thebackla h of the HPG drivewont deteriorate over time
One method commonlyemployed toprovide low orzero backlash ill planetarygear systems is to create atight fit between all of thegears However this methodis subject to gear tooth wearand over the life of the gear-box the backl3sll can increasesignificantly
Another method is to usepreloaded bevel gears as panof the mechanism Shimsforce the bevel gears togetheraxially which forces a raclialpreload in the planetary gearsBacklash in this type of sys-tem also increases over timebecause of gear tooth wear
Because of the flexibledefermation of the planetaryring gear the HPG gearheadautomaucally compensatesfor gear tooth wear 81 Dellisays This helps ensure con-sistent backlash throughoutthe rated life of the gearbox
The H~ Series planetarygearheads have standardbacklash of less than 3 arc-minutes and they can beordered with 1 arc-minute ofbacklash as an option Theyare available in ratios from51 to 331
Cirele3mwwwpow9rrsnsmlssloncom bull wwwge8rtechnQJoycom bull GEAR TECHNOLOGYmiddotmiddot MAYJUNE 2001
MicmgearsFor Use In Tlhe
IHuman MachineIn a Hungarian lab using a
microscopes laser research-ers are creating gears androtors thinner than a humanhair ADd willie hair growsout of the body the re-searchers want to put theirgears and rotors into the bodyin microsoopic machines forconducting experiments
Its like the movie innerSpace wilh Dennis Quaidsays researcher p~ OrmosThe machines could be builtso small that they would fitinto blood vessels for analyz-ing blood
To create the gears androtors Onnos uses hardenedliquid photopolymer Butunlike the micropans and their
pos ible lise the material isntnearly as exotic
Dentists use it a letann os says The material isthe same as whats II ed fortooth fillings hardened withultraviolet light
Ormes developed the tech-nique with Fewr Galajda in alittle more than a year--Just now weare perfectingit Ormes acids that hed likero use the technique in lessthan a year to build everaltypes of machine
Willi a doctorate ill phys-ics Ormos belongs to theHungarian Academy of Sci-ences and works at itsBiological Research Centrelocated in Szeged Ormos isdirector of the centres Insti-tnte of Biophy it Galajda istis doctoral snrdent
We study thephysics of
Created undBr II microscope threll rotan appear in front of the Dak-likeIJIIJ1Jc lif bullbullbull II 110mB n bairLivingsystems Ormes says Ormos and Galajdas gearsHe acids lliat theres a strong and rotors could be usedjndrive ill biology toward minia- that study as parts in micro-turizing which has a lot of scopic biochemical device promise in it The micromachines would be
bull accuracybull reliabilitybull maintolinCibilitybull Hexibilily performancebull and life cyde eest
AI Klingelnberg the point ofprecision is 10 help you controlyour gear manufocturing pro-cess and improve gearqudlitywith measuring systems thaIare benchmarks for
Klingelnberg measuringtechnology contaeLiebherr Gear Technology Co1465 Woodland DriveSaline MI4B 176-1259
_------------REVOLUTIONS------------_used ro investigate living sys-terns at a cellular level per-mitting the movement of indi-vidual ceIls-even individuallarge molecules Ormos says~ts a very precise tool thatcan be used in biology
With such machines scien-tists could introduce chemi-cals into cells manipulatetheir reactions and maintainthose cells environmentspumping different solutions todifferent regions They couldmeasure cell properties toselect certaia cells create achannel for transporting thosecells and transport the cellsindividually They could alsoremove compounds fromcells even destroy cells
The gears and rotors diam-eters can be as small as twomicrons A human hales diam-eter is about 100 microns At
two microns the parts canweigh as little as ]()LO grams
Ormos and GaIajda maketheir microparts by placingliquid photopolymer under amicroscope then moving acomputer-controlled laser fo-cus into the microscopeWhereverthe focus movesthe liquid becomes hardenedIf it moves in a gear shape thefocus makes a hardened gear
We can create a three-dimensionalobject that is ascomplicated as we wantOrmes says
DUI theres a wri nkle inthe technology that needs tobe ironed out
The micro gears are rotatedby the microrotors The micro-rotors are rotated by light
Its not easy to introducelight into the blood vesselsOmms says
But he adds there may be asolution to that problemOrmos explains that themachines in the body could bepowered by tightlfit wereintroduced effectively-via athin optic fiber for example
In similar research SandiaNational Laboratories in NewMexico has used chemicalmiddotelching to create microgearsand experimental micro-engines electric motors no
1 larger than a grain of sandOrmos started his research
j to understand how light causesI different trapped particles toj rotate But he later realizedi such light-induced rotationi could have useful applicationsI
1 It was not really the areaI
1 in which we were deliberately
II
moving he saysOnnos is unsure about the
techniques future-Whether
this can be commercialized ornot isnt clear Still he andOalajda are testing resins todecide which works best forcreating their gears and rotors
I think the possibilities arereally uolimited Ormes saysAnything that can be donewith larger machines can bedone with smaller ones too
Cirde302
Tbullbull V
If you found tIriI IfticfI ofinterest andor UIefuI
~
l1~~
Phone + 1-734-429-7225Fax 1-734-429-2294wwwpointofprecisioncominfopointofprecisioncom
bull 1INDUSTRV NEWS _
Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
S86 HilliardStreet RO Box 1898 Manchester CT06045-1898 USATelephone 86() 1649-0000 bull Fax 860 645-629g
Home Page httpwwwpurdytransmissionscomf-Mail salespurrlytransmissonsfOffl
Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
Fifty years or VARI-ROLL applications providebull Production Composite Inspectionbull Custom Design amp Build Part Gear Mounting Fixturesbull Standard Mounting Fixtures - Spurs Helicals Pinion Shafts
Worms Throated Worms Bevels Internals
When coupled with the VARI-PC Composite Gear AnalysisSystem will providebull Reduced Inspection Cost Improved Accuracy Historical Record Keepingbull Serialization of Partsbull Interface to SPC programsExperience the difference See why customers worldwide havechosen the VARI-ROLUVARImiddotPC For further informationplease contact us
Precision Gage ce Inc100 Shore Drive Burr Ridge IL 60521
630-655-2121 Fax630-6S5-3073wwwpredsiongagecocom
United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
CIRCLE 1Ji
ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
Will YoI TIIiIk bullbullIf you found 1his column of inbaIt lIIdIoruseful pIe
If did notcn forflll coIumn _
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16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
S- Amcricllinc
Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
far __ illfonnalion eIIouI bull prIIIiucI DIIHrYiCJ JdHftIMd Ii hil iUIIII IIf 6_rfthohlfr I~-IM appropriate IIIUIIIber IIIIM lIIdr IInpg_ Callli MIlput ilia clrd in Ihe lIIIiI
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IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
AIW Sy5lcmsAero Gar [nc
AGMAAja M~ Corp
AmmCllll MeIlll T~1l Co
Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
1_1 I)CiuIG~tIJ TlaquohnoIDV
Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
TIle Gleason WollksHolroyd
lndex Technologies lee
Inducloheai
lnsco Corplnterstate Tool CorpTW H~ltIlandKim ~lnberg S(IIme GmbHKprOf AlneriQ LLCKoro Sluupening ServiceKrei~r~hleCoonl Ine
Mew Media loeb amp More
MiCroGCATMidwest Gear amp Tool IncMidWeIgtlGeM Corp
acbil Mrchjning Techno[ogy Co
iagllIll Gear Corp
Nona Gear Failure Semiruur
On-Iine ServIlCS Inc
Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
Profile Engmccnog IncPru-Oew Co locThe Purdy Corp
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GROUND GEARS- TeD or ren lhousandFor small to medium Quantities of spurs or helicals that have tomeet close-tolerance AGMA or DIN specs our Relshauer grindersand MampM gear analysis systems arelhe perfect combination
For Long runs we Offer the unique lIebherr CBN grindingprecess with full SPC Quality cOrtroland documentation
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An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
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WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
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CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
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For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
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Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
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they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
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We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
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We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
-
PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
PUBLISHERS PAGEsays the company began approachingthose customers who could best takeadvantage of Avon Gears core compe-tencies One of those companies wasCaterpillar
By making a commitment to special-ize in a certain type of gear for a certainmarket segment Avon Gear was able tocapture Caterpillars business That busi-ness in tum allowed the company anopportunity to invest in new equipment
and training to provide even greater com-petitive advantage
Today according to Davis AvonGear is one of the most important sup-pliers for Caterpillars transmissionbusiness unit Working together thecompanies are able to provide theworld-class manufacturing quality andpricing on gear components that helpkeep Caterpillars equipment competi-tive in the world market Furiliermore
bullIng
Remove nicks buns hest treat scaleand Improve gear tooth surface
Onr 30 J8IlI ago morllaar1lalll developed the gelDbilihlmidlddDglllllllilnnJllOC8llPat JOU trust In tbe people who Invented the process
MAatlNE FEATURESINCLUDEbull Fully automated systemsbull High speed machinesbull Patented Gerac
Oscillation Systembull Automatic spherical
position Ingbull Trl-varlable die designbull Horizontal or vertical axis
machinesbull Variety of gear types
For additional information on IhHuBurnishingandor Functional flfiu
Inectionvisit our website ottIVIIVw ilWgearscom
ITP1tl HeartlandWorkilll9 components 01 theHorizontal Bumisher
1205 36th Avenue WestAlexandria MN 56308 USA
Ph (320) 762-8782Fax (320) 782-5280
E-mail ItwgeaISOrea-alpoom
8 MAYJU NE 2001 GEAFi TECHNOLOGYmiddot www9Ilartllchnolo9ycom bull wWWpowllrtransmissioncom
~c~l(JoldsteinPublisher amp Editor-in-Chief
the processes machines and expertisedeveloped by Avon Gear have given thecompany the ability to sell gears ofworld-class quality and price to othercustomers with similar needs
In fact Davis saysthe partnershipbetween these two companies has devel-oped into one of mutua] trust and plan-ning Like most successful partnershipsits now in the best interest of each partythat the other doesnt fail
Like Caterpillar and Avon Gear eachof our own companies has core compe-tencies-things that are central to ourbusiness which years of working in cer-tain areas allow us to do better than othercompanies without the same focusFinding those things concentrating onthem and expanding on them can helpmake us more successful
Not finding and developing your corecompetency can have the opposite effectIts true that some companies will bemore focused than others But even themost generalist of companies has corecompetencies For example a general-purpose gear job shop with a broad rangeof equipment and tooling might not seemto have a specific niche Neverthelessthat same company might specialize infast turnaround design assistance orextremely high quality each of whichcould be developed for greater competi-tive advantage in certain marketplaces
You can learn more about your corecompetencies by choice or by necessityIf you do so by choice perhaps you II beable to make intelligent decisions aboutyour companys operations as Caterpil-lar did However if you wait you may beforced to learn about your core compe-tencies the hard way Perhaps youll beable to act quickly enough to save yourcompany as Avon Gear did But thenagain
For 96 years the Bodine name has symbollized quality in power transmissionand motlon control IBodine EIectric Company pioneered the concept ot fracticnalhorsepower motors with integrall gear reducers We calrefully guard our reputationfor producing the quietest smoothest Iiongest-life products in the industry
Now you can tnccrporate those same higlhstandards of qualityrellabtlltyand on-time deillivelry iinto your products that require filneand medium pitch open gears from hundreds to hundreds oftLo - - - ~ -d -nousancs
Bodine Gear Manufacturing employs state-of-the-art eNG gearmanufactuning and inspection technology with in-depthengineening support to service your most demandinQappucattons For skived gears we can be your most competitiivecompetent source
To learn more about Bodiine Gear Manufacturing and get your Free Bodiine Gears capvisit ww-wBodineGearscomFreeCaphtm or call toll flree 877-4GEARS9
Sales Representative inquiries welcome
CIRetIE 109
~-~ -- - ------------------
Quieter GearsEngineered Metals
Theres only one way to ensure thatthe gears you produce win always deliversuperior and quiet performance Make suretheyre bred from quaUty stock
Dura-Bars continuous-cast gray and ductileiron performs like free-machining steel with anImportantadded bonus - quieter operation
Like steel Dura-Bar can he austemperedthrough-hardened flame-hardened or induction-hardened for added wear resistance Butthesuperior noise and vibration damping characteristicsof Dura-Bar make for quieter runninggears AndDura-Bar is 10Ughter than steel
Dura-Bar round bars are avatlable In diametersnnging from 58~ to 20 and lengths of 6-20 So youwont need to make major changes in your machining equipment And our extensive mventory means Dura-Bar is available now - when you need U
Wben Its quaUtymaterial quiet performance and quick deUverythatcount look to continuous-cast Dura-Bar for your gear production needs
DURA~BARreg 1-S00BAR-MILL (227-6455) - 815-338-7800 -Fax 815-338middot15492100 West Lake Shore Drive Woodstock H-60098-7497Web Site wwwdiutamiddotbalcom bull E-mail salesdura-barcQmContinuous Cast Iron Bar Stock
Contact us for the latest dat8iOD geuDouemiddot
CIRCe -1$8
REVOLUTIONS -- _
Hlarmonic ConceptsJazz lp
Planetary DesiglnIn the world of planetary
servo drives precision iseverything Advertisementsabound fOJ ervo gear driveswith extremely low or evenzere backlash With that typeof drive in high demand man-ufacturers have done every-thing they can to tighten theirdesigns-thmugh more exact-ing tolerances tighter assem-bly and better materials
Instead of tightening onemanufacturer of planetaryservo drives has tried loosen-
mg in order [0 provide the lowbacklash that manufacturers ofrobotics and other precise posi-
tioning equipment requireThat loosening bas nothing
te do with the manufacturingtolerances or assembly Pre-cision manufacturing is stillrequired Ithas to do with atype of flexibility borrowedfrom a related technologyharmonic drive gearing
Harmonic drive gearinghas long been known for itslow backlash high precisionand compact design Har-monic drive systems use a cir-cular spline a flex spline and
Cut-away view of the HPG gear drive from HIl Systems
me HPG drive includes II 11111 lIear 10 cantro bacldash(defoRnltion 8xallllerated for mustrative purposes
wavegenera~or to createextremely high ratios in a sin-gle reduction One of theadvantages of the harmonicdrive system is that the flexspline deforms as it rotates tokeep its teeth fully loadedagainst the circular spline alaU times
Engineers at HD Systems ofHauppauge NY haveliguredout how to apply the deforma-tion concept of harmonic drivesystems to planetary gears aswell Instead of a flexible imlerspline bull the HPG harmonicplanetary gearheads use aflexible outer ring gear to pre-load the gearset
The flexible outer ringgear of the HPG gearheadcreates a continually adju l-ing backlash compensationmethod The ring gear is thin-ner in the radial directionthan a typical ring gear Thismakes it radjaUy flexible yettorsionally stiff says HDSystems marketing managerBrian St Denis As normal
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gear wear occurs any in-crease in space between the
jteeth is immediately compen- Isated by the preload in the ring gear The concept is as if Ithe ring gear is a spring in the Iradial direction
The system employed byHD Systems has a huge advan-tage over those commonlyemployed by other maaufac-turers says St Denis Thebackla h of the HPG drivewont deteriorate over time
One method commonlyemployed toprovide low orzero backlash ill planetarygear systems is to create atight fit between all of thegears However this methodis subject to gear tooth wearand over the life of the gear-box the backl3sll can increasesignificantly
Another method is to usepreloaded bevel gears as panof the mechanism Shimsforce the bevel gears togetheraxially which forces a raclialpreload in the planetary gearsBacklash in this type of sys-tem also increases over timebecause of gear tooth wear
Because of the flexibledefermation of the planetaryring gear the HPG gearheadautomaucally compensatesfor gear tooth wear 81 Dellisays This helps ensure con-sistent backlash throughoutthe rated life of the gearbox
The H~ Series planetarygearheads have standardbacklash of less than 3 arc-minutes and they can beordered with 1 arc-minute ofbacklash as an option Theyare available in ratios from51 to 331
Cirele3mwwwpow9rrsnsmlssloncom bull wwwge8rtechnQJoycom bull GEAR TECHNOLOGYmiddotmiddot MAYJUNE 2001
MicmgearsFor Use In Tlhe
IHuman MachineIn a Hungarian lab using a
microscopes laser research-ers are creating gears androtors thinner than a humanhair ADd willie hair growsout of the body the re-searchers want to put theirgears and rotors into the bodyin microsoopic machines forconducting experiments
Its like the movie innerSpace wilh Dennis Quaidsays researcher p~ OrmosThe machines could be builtso small that they would fitinto blood vessels for analyz-ing blood
To create the gears androtors Onnos uses hardenedliquid photopolymer Butunlike the micropans and their
pos ible lise the material isntnearly as exotic
Dentists use it a letann os says The material isthe same as whats II ed fortooth fillings hardened withultraviolet light
Ormes developed the tech-nique with Fewr Galajda in alittle more than a year--Just now weare perfectingit Ormes acids that hed likero use the technique in lessthan a year to build everaltypes of machine
Willi a doctorate ill phys-ics Ormos belongs to theHungarian Academy of Sci-ences and works at itsBiological Research Centrelocated in Szeged Ormos isdirector of the centres Insti-tnte of Biophy it Galajda istis doctoral snrdent
We study thephysics of
Created undBr II microscope threll rotan appear in front of the Dak-likeIJIIJ1Jc lif bullbullbull II 110mB n bairLivingsystems Ormes says Ormos and Galajdas gearsHe acids lliat theres a strong and rotors could be usedjndrive ill biology toward minia- that study as parts in micro-turizing which has a lot of scopic biochemical device promise in it The micromachines would be
bull accuracybull reliabilitybull maintolinCibilitybull Hexibilily performancebull and life cyde eest
AI Klingelnberg the point ofprecision is 10 help you controlyour gear manufocturing pro-cess and improve gearqudlitywith measuring systems thaIare benchmarks for
Klingelnberg measuringtechnology contaeLiebherr Gear Technology Co1465 Woodland DriveSaline MI4B 176-1259
_------------REVOLUTIONS------------_used ro investigate living sys-terns at a cellular level per-mitting the movement of indi-vidual ceIls-even individuallarge molecules Ormos says~ts a very precise tool thatcan be used in biology
With such machines scien-tists could introduce chemi-cals into cells manipulatetheir reactions and maintainthose cells environmentspumping different solutions todifferent regions They couldmeasure cell properties toselect certaia cells create achannel for transporting thosecells and transport the cellsindividually They could alsoremove compounds fromcells even destroy cells
The gears and rotors diam-eters can be as small as twomicrons A human hales diam-eter is about 100 microns At
two microns the parts canweigh as little as ]()LO grams
Ormos and GaIajda maketheir microparts by placingliquid photopolymer under amicroscope then moving acomputer-controlled laser fo-cus into the microscopeWhereverthe focus movesthe liquid becomes hardenedIf it moves in a gear shape thefocus makes a hardened gear
We can create a three-dimensionalobject that is ascomplicated as we wantOrmes says
DUI theres a wri nkle inthe technology that needs tobe ironed out
The micro gears are rotatedby the microrotors The micro-rotors are rotated by light
Its not easy to introducelight into the blood vesselsOmms says
But he adds there may be asolution to that problemOrmos explains that themachines in the body could bepowered by tightlfit wereintroduced effectively-via athin optic fiber for example
In similar research SandiaNational Laboratories in NewMexico has used chemicalmiddotelching to create microgearsand experimental micro-engines electric motors no
1 larger than a grain of sandOrmos started his research
j to understand how light causesI different trapped particles toj rotate But he later realizedi such light-induced rotationi could have useful applicationsI
1 It was not really the areaI
1 in which we were deliberately
II
moving he saysOnnos is unsure about the
techniques future-Whether
this can be commercialized ornot isnt clear Still he andOalajda are testing resins todecide which works best forcreating their gears and rotors
I think the possibilities arereally uolimited Ormes saysAnything that can be donewith larger machines can bedone with smaller ones too
Cirde302
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Phone + 1-734-429-7225Fax 1-734-429-2294wwwpointofprecisioncominfopointofprecisioncom
bull 1INDUSTRV NEWS _
Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
S86 HilliardStreet RO Box 1898 Manchester CT06045-1898 USATelephone 86() 1649-0000 bull Fax 860 645-629g
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Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
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Worms Throated Worms Bevels Internals
When coupled with the VARI-PC Composite Gear AnalysisSystem will providebull Reduced Inspection Cost Improved Accuracy Historical Record Keepingbull Serialization of Partsbull Interface to SPC programsExperience the difference See why customers worldwide havechosen the VARI-ROLUVARImiddotPC For further informationplease contact us
Precision Gage ce Inc100 Shore Drive Burr Ridge IL 60521
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United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
CIRCLE 1Ji
ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
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16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
S- Amcricllinc
Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
far __ illfonnalion eIIouI bull prIIIiucI DIIHrYiCJ JdHftIMd Ii hil iUIIII IIf 6_rfthohlfr I~-IM appropriate IIIUIIIber IIIIM lIIdr IInpg_ Callli MIlput ilia clrd in Ihe lIIIiI
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IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
AIW Sy5lcmsAero Gar [nc
AGMAAja M~ Corp
AmmCllll MeIlll T~1l Co
Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
1_1 I)CiuIG~tIJ TlaquohnoIDV
Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
TIle Gleason WollksHolroyd
lndex Technologies lee
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lnsco Corplnterstate Tool CorpTW H~ltIlandKim ~lnberg S(IIme GmbHKprOf AlneriQ LLCKoro Sluupening ServiceKrei~r~hleCoonl Ine
Mew Media loeb amp More
MiCroGCATMidwest Gear amp Tool IncMidWeIgtlGeM Corp
acbil Mrchjning Techno[ogy Co
iagllIll Gear Corp
Nona Gear Failure Semiruur
On-Iine ServIlCS Inc
Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
Profile Engmccnog IncPru-Oew Co locThe Purdy Corp
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An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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If you would like more information abouta-tllo Bear CO circle1fUATA Geelllld circ _00 Drive a Gear Ltd clrcl aU-If you would like to respond to this or any other articlein this edition of GeBr Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-6618
A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
T Us YOII Think If you found this article of interest andor usefulplease circle aMIf you did not care for this article circle ~
If you would like more information about Pialllurgh ccirc ~If you would like to respond to this or any other articlein this edition of Gear Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-661 B
WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
Solutions for yourgear manufacturingneeds~owefiedbySamputensil
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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availableFor more Information contact
Aero Gear Inc~050Drt lUllRd Wllldor CT IDIiImltTel (860) 6880888IFax 1860) 285-3514
emsll buygsarsiaerogearcom bull wwwaerogearcoml
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
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static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
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Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
I--+--+--t--~ T1RUE DIMENSION GEAR INmiddotSPEC
Provides actual overballpin measurmenof any helical orgear or splin WiLU t-
the need ofcostlysetting masters
Ga~ Division
d Tool _I
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851 OHIO PIKE middotCINCINNATI OHIO 45245 bull (513) 152-6000 bull FAX (513) 75205599
CIRCLIE 13jt
Learn mare at ShON Central
bull Exhlibiitor Liistbull Booth Descriptions
bull NEW THIS YIEAIR Online Videos
Plan our visit to tile sllow months in advainceat Shaw Central
wwwgeartechnologeJlpocomwpowerrtatlamfsslotlcom WWWg9Iut9chnoloflycom GEAR TECHNOLOGYmiddot MAYIJUNIE 2001 45
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
I till Us DIIIk
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
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SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
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lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
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For 96 years the Bodine name has symbollized quality in power transmissionand motlon control IBodine EIectric Company pioneered the concept ot fracticnalhorsepower motors with integrall gear reducers We calrefully guard our reputationfor producing the quietest smoothest Iiongest-life products in the industry
Now you can tnccrporate those same higlhstandards of qualityrellabtlltyand on-time deillivelry iinto your products that require filneand medium pitch open gears from hundreds to hundreds oftLo - - - ~ -d -nousancs
Bodine Gear Manufacturing employs state-of-the-art eNG gearmanufactuning and inspection technology with in-depthengineening support to service your most demandinQappucattons For skived gears we can be your most competitiivecompetent source
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Like steel Dura-Bar can he austemperedthrough-hardened flame-hardened or induction-hardened for added wear resistance Butthesuperior noise and vibration damping characteristicsof Dura-Bar make for quieter runninggears AndDura-Bar is 10Ughter than steel
Dura-Bar round bars are avatlable In diametersnnging from 58~ to 20 and lengths of 6-20 So youwont need to make major changes in your machining equipment And our extensive mventory means Dura-Bar is available now - when you need U
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REVOLUTIONS -- _
Hlarmonic ConceptsJazz lp
Planetary DesiglnIn the world of planetary
servo drives precision iseverything Advertisementsabound fOJ ervo gear driveswith extremely low or evenzere backlash With that typeof drive in high demand man-ufacturers have done every-thing they can to tighten theirdesigns-thmugh more exact-ing tolerances tighter assem-bly and better materials
Instead of tightening onemanufacturer of planetaryservo drives has tried loosen-
mg in order [0 provide the lowbacklash that manufacturers ofrobotics and other precise posi-
tioning equipment requireThat loosening bas nothing
te do with the manufacturingtolerances or assembly Pre-cision manufacturing is stillrequired Ithas to do with atype of flexibility borrowedfrom a related technologyharmonic drive gearing
Harmonic drive gearinghas long been known for itslow backlash high precisionand compact design Har-monic drive systems use a cir-cular spline a flex spline and
Cut-away view of the HPG gear drive from HIl Systems
me HPG drive includes II 11111 lIear 10 cantro bacldash(defoRnltion 8xallllerated for mustrative purposes
wavegenera~or to createextremely high ratios in a sin-gle reduction One of theadvantages of the harmonicdrive system is that the flexspline deforms as it rotates tokeep its teeth fully loadedagainst the circular spline alaU times
Engineers at HD Systems ofHauppauge NY haveliguredout how to apply the deforma-tion concept of harmonic drivesystems to planetary gears aswell Instead of a flexible imlerspline bull the HPG harmonicplanetary gearheads use aflexible outer ring gear to pre-load the gearset
The flexible outer ringgear of the HPG gearheadcreates a continually adju l-ing backlash compensationmethod The ring gear is thin-ner in the radial directionthan a typical ring gear Thismakes it radjaUy flexible yettorsionally stiff says HDSystems marketing managerBrian St Denis As normal
Wecome to Revolu-
Iions th column tIItbrings you the Illtest
most up-to-dBtl ndeasY-Io-read informll-
tion bout the people
nd technology of thegell industry Revolu-
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Technologv PO Box1426 flk Grore VillageIt 60009 or fx (HI)
431-6618 If youd like
more infomllltion sbout
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gear wear occurs any in-crease in space between the
jteeth is immediately compen- Isated by the preload in the ring gear The concept is as if Ithe ring gear is a spring in the Iradial direction
The system employed byHD Systems has a huge advan-tage over those commonlyemployed by other maaufac-turers says St Denis Thebackla h of the HPG drivewont deteriorate over time
One method commonlyemployed toprovide low orzero backlash ill planetarygear systems is to create atight fit between all of thegears However this methodis subject to gear tooth wearand over the life of the gear-box the backl3sll can increasesignificantly
Another method is to usepreloaded bevel gears as panof the mechanism Shimsforce the bevel gears togetheraxially which forces a raclialpreload in the planetary gearsBacklash in this type of sys-tem also increases over timebecause of gear tooth wear
Because of the flexibledefermation of the planetaryring gear the HPG gearheadautomaucally compensatesfor gear tooth wear 81 Dellisays This helps ensure con-sistent backlash throughoutthe rated life of the gearbox
The H~ Series planetarygearheads have standardbacklash of less than 3 arc-minutes and they can beordered with 1 arc-minute ofbacklash as an option Theyare available in ratios from51 to 331
Cirele3mwwwpow9rrsnsmlssloncom bull wwwge8rtechnQJoycom bull GEAR TECHNOLOGYmiddotmiddot MAYJUNE 2001
MicmgearsFor Use In Tlhe
IHuman MachineIn a Hungarian lab using a
microscopes laser research-ers are creating gears androtors thinner than a humanhair ADd willie hair growsout of the body the re-searchers want to put theirgears and rotors into the bodyin microsoopic machines forconducting experiments
Its like the movie innerSpace wilh Dennis Quaidsays researcher p~ OrmosThe machines could be builtso small that they would fitinto blood vessels for analyz-ing blood
To create the gears androtors Onnos uses hardenedliquid photopolymer Butunlike the micropans and their
pos ible lise the material isntnearly as exotic
Dentists use it a letann os says The material isthe same as whats II ed fortooth fillings hardened withultraviolet light
Ormes developed the tech-nique with Fewr Galajda in alittle more than a year--Just now weare perfectingit Ormes acids that hed likero use the technique in lessthan a year to build everaltypes of machine
Willi a doctorate ill phys-ics Ormos belongs to theHungarian Academy of Sci-ences and works at itsBiological Research Centrelocated in Szeged Ormos isdirector of the centres Insti-tnte of Biophy it Galajda istis doctoral snrdent
We study thephysics of
Created undBr II microscope threll rotan appear in front of the Dak-likeIJIIJ1Jc lif bullbullbull II 110mB n bairLivingsystems Ormes says Ormos and Galajdas gearsHe acids lliat theres a strong and rotors could be usedjndrive ill biology toward minia- that study as parts in micro-turizing which has a lot of scopic biochemical device promise in it The micromachines would be
bull accuracybull reliabilitybull maintolinCibilitybull Hexibilily performancebull and life cyde eest
AI Klingelnberg the point ofprecision is 10 help you controlyour gear manufocturing pro-cess and improve gearqudlitywith measuring systems thaIare benchmarks for
Klingelnberg measuringtechnology contaeLiebherr Gear Technology Co1465 Woodland DriveSaline MI4B 176-1259
_------------REVOLUTIONS------------_used ro investigate living sys-terns at a cellular level per-mitting the movement of indi-vidual ceIls-even individuallarge molecules Ormos says~ts a very precise tool thatcan be used in biology
With such machines scien-tists could introduce chemi-cals into cells manipulatetheir reactions and maintainthose cells environmentspumping different solutions todifferent regions They couldmeasure cell properties toselect certaia cells create achannel for transporting thosecells and transport the cellsindividually They could alsoremove compounds fromcells even destroy cells
The gears and rotors diam-eters can be as small as twomicrons A human hales diam-eter is about 100 microns At
two microns the parts canweigh as little as ]()LO grams
Ormos and GaIajda maketheir microparts by placingliquid photopolymer under amicroscope then moving acomputer-controlled laser fo-cus into the microscopeWhereverthe focus movesthe liquid becomes hardenedIf it moves in a gear shape thefocus makes a hardened gear
We can create a three-dimensionalobject that is ascomplicated as we wantOrmes says
DUI theres a wri nkle inthe technology that needs tobe ironed out
The micro gears are rotatedby the microrotors The micro-rotors are rotated by light
Its not easy to introducelight into the blood vesselsOmms says
But he adds there may be asolution to that problemOrmos explains that themachines in the body could bepowered by tightlfit wereintroduced effectively-via athin optic fiber for example
In similar research SandiaNational Laboratories in NewMexico has used chemicalmiddotelching to create microgearsand experimental micro-engines electric motors no
1 larger than a grain of sandOrmos started his research
j to understand how light causesI different trapped particles toj rotate But he later realizedi such light-induced rotationi could have useful applicationsI
1 It was not really the areaI
1 in which we were deliberately
II
moving he saysOnnos is unsure about the
techniques future-Whether
this can be commercialized ornot isnt clear Still he andOalajda are testing resins todecide which works best forcreating their gears and rotors
I think the possibilities arereally uolimited Ormes saysAnything that can be donewith larger machines can bedone with smaller ones too
Cirde302
Tbullbull V
If you found tIriI IfticfI ofinterest andor UIefuI
~
l1~~
Phone + 1-734-429-7225Fax 1-734-429-2294wwwpointofprecisioncominfopointofprecisioncom
bull 1INDUSTRV NEWS _
Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
S86 HilliardStreet RO Box 1898 Manchester CT06045-1898 USATelephone 86() 1649-0000 bull Fax 860 645-629g
Home Page httpwwwpurdytransmissionscomf-Mail salespurrlytransmissonsfOffl
Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
Fifty years or VARI-ROLL applications providebull Production Composite Inspectionbull Custom Design amp Build Part Gear Mounting Fixturesbull Standard Mounting Fixtures - Spurs Helicals Pinion Shafts
Worms Throated Worms Bevels Internals
When coupled with the VARI-PC Composite Gear AnalysisSystem will providebull Reduced Inspection Cost Improved Accuracy Historical Record Keepingbull Serialization of Partsbull Interface to SPC programsExperience the difference See why customers worldwide havechosen the VARI-ROLUVARImiddotPC For further informationplease contact us
Precision Gage ce Inc100 Shore Drive Burr Ridge IL 60521
630-655-2121 Fax630-6S5-3073wwwpredsiongagecocom
United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
CIRCLE 1Ji
ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
Will YoI TIIiIk bullbullIf you found 1his column of inbaIt lIIdIoruseful pIe
If did notcn forflll coIumn _
I
If you would like to mpond to this or anyother article In tltil adlllon of 60rTMhntw=faxvour ~totheIIlIfIdon If SIDU manqlnt edIIur ItIMJ437-1818 or I8ftd melII1D ~com
16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
S- Amcricllinc
Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
far __ illfonnalion eIIouI bull prIIIiucI DIIHrYiCJ JdHftIMd Ii hil iUIIII IIf 6_rfthohlfr I~-IM appropriate IIIUIIIber IIIIM lIIdr IInpg_ Callli MIlput ilia clrd in Ihe lIIIiI
11IYIDURWID IpoundADERIIESPONSE SYSTEMIIGoio wwwg bullbull nchlHlltlflyct1tJlmlrtm III Irlqlllll1 additiDnal infDmIationram Iny dverti r in hil iUlle Yow IrlqPesl will bullbull IIId til the Idvertiserwithl 24 bllm IDlluper-fU1 tllmaround I
IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
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AGMAAja M~ Corp
AmmCllll MeIlll T~1l Co
Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
1_1 I)CiuIG~tIJ TlaquohnoIDV
Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
TIle Gleason WollksHolroyd
lndex Technologies lee
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lnsco Corplnterstate Tool CorpTW H~ltIlandKim ~lnberg S(IIme GmbHKprOf AlneriQ LLCKoro Sluupening ServiceKrei~r~hleCoonl Ine
Mew Media loeb amp More
MiCroGCATMidwest Gear amp Tool IncMidWeIgtlGeM Corp
acbil Mrchjning Techno[ogy Co
iagllIll Gear Corp
Nona Gear Failure Semiruur
On-Iine ServIlCS Inc
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steel arborFeather lighthydraulicarbors can bemanufactured wilhrunout as low as2 microns The clampingsleeves are replaceabte Thistoolingl is suitable for measuringtesting balancinggear grindingand other applications
T_~O _--UIoIt--~-- ~~-~-~_ _ -1IIrIndIrit bull T-g bull LDbull OD ~-IumIn~
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An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
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WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
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1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
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For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
If you found this article of interest andoruseful pI sa circle
MAYJUNE 2001 bull GiEAR TECHNQlQGY wWlIgurechlloloQycom bull wwwpowerlrslIsmluloncom
GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
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_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
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CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
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HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
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IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
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CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
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Direct your inquiries toRon lfIumphrerGeneral Manage
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ICIINTACT US FOR IIQIJOTE TiIlDAYI
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bull Cost effective gear tooth grindinglspecialists
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
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HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
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Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
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For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
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HOB SHARPIENIINGbull State-of-the-art eNC sharpening
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bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
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Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Theres only one way to ensure thatthe gears you produce win always deliversuperior and quiet performance Make suretheyre bred from quaUty stock
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Like steel Dura-Bar can he austemperedthrough-hardened flame-hardened or induction-hardened for added wear resistance Butthesuperior noise and vibration damping characteristicsof Dura-Bar make for quieter runninggears AndDura-Bar is 10Ughter than steel
Dura-Bar round bars are avatlable In diametersnnging from 58~ to 20 and lengths of 6-20 So youwont need to make major changes in your machining equipment And our extensive mventory means Dura-Bar is available now - when you need U
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REVOLUTIONS -- _
Hlarmonic ConceptsJazz lp
Planetary DesiglnIn the world of planetary
servo drives precision iseverything Advertisementsabound fOJ ervo gear driveswith extremely low or evenzere backlash With that typeof drive in high demand man-ufacturers have done every-thing they can to tighten theirdesigns-thmugh more exact-ing tolerances tighter assem-bly and better materials
Instead of tightening onemanufacturer of planetaryservo drives has tried loosen-
mg in order [0 provide the lowbacklash that manufacturers ofrobotics and other precise posi-
tioning equipment requireThat loosening bas nothing
te do with the manufacturingtolerances or assembly Pre-cision manufacturing is stillrequired Ithas to do with atype of flexibility borrowedfrom a related technologyharmonic drive gearing
Harmonic drive gearinghas long been known for itslow backlash high precisionand compact design Har-monic drive systems use a cir-cular spline a flex spline and
Cut-away view of the HPG gear drive from HIl Systems
me HPG drive includes II 11111 lIear 10 cantro bacldash(defoRnltion 8xallllerated for mustrative purposes
wavegenera~or to createextremely high ratios in a sin-gle reduction One of theadvantages of the harmonicdrive system is that the flexspline deforms as it rotates tokeep its teeth fully loadedagainst the circular spline alaU times
Engineers at HD Systems ofHauppauge NY haveliguredout how to apply the deforma-tion concept of harmonic drivesystems to planetary gears aswell Instead of a flexible imlerspline bull the HPG harmonicplanetary gearheads use aflexible outer ring gear to pre-load the gearset
The flexible outer ringgear of the HPG gearheadcreates a continually adju l-ing backlash compensationmethod The ring gear is thin-ner in the radial directionthan a typical ring gear Thismakes it radjaUy flexible yettorsionally stiff says HDSystems marketing managerBrian St Denis As normal
Wecome to Revolu-
Iions th column tIItbrings you the Illtest
most up-to-dBtl ndeasY-Io-read informll-
tion bout the people
nd technology of thegell industry Revolu-
Uons welcomes OUsubmissions PleBSe
sefid them to Gear
Technologv PO Box1426 flk Grore VillageIt 60009 or fx (HI)
431-6618 If youd like
more infomllltion sbout
flY of the articles that
appellrpiliS cirelli theappropiate number on
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gear wear occurs any in-crease in space between the
jteeth is immediately compen- Isated by the preload in the ring gear The concept is as if Ithe ring gear is a spring in the Iradial direction
The system employed byHD Systems has a huge advan-tage over those commonlyemployed by other maaufac-turers says St Denis Thebackla h of the HPG drivewont deteriorate over time
One method commonlyemployed toprovide low orzero backlash ill planetarygear systems is to create atight fit between all of thegears However this methodis subject to gear tooth wearand over the life of the gear-box the backl3sll can increasesignificantly
Another method is to usepreloaded bevel gears as panof the mechanism Shimsforce the bevel gears togetheraxially which forces a raclialpreload in the planetary gearsBacklash in this type of sys-tem also increases over timebecause of gear tooth wear
Because of the flexibledefermation of the planetaryring gear the HPG gearheadautomaucally compensatesfor gear tooth wear 81 Dellisays This helps ensure con-sistent backlash throughoutthe rated life of the gearbox
The H~ Series planetarygearheads have standardbacklash of less than 3 arc-minutes and they can beordered with 1 arc-minute ofbacklash as an option Theyare available in ratios from51 to 331
Cirele3mwwwpow9rrsnsmlssloncom bull wwwge8rtechnQJoycom bull GEAR TECHNOLOGYmiddotmiddot MAYJUNE 2001
MicmgearsFor Use In Tlhe
IHuman MachineIn a Hungarian lab using a
microscopes laser research-ers are creating gears androtors thinner than a humanhair ADd willie hair growsout of the body the re-searchers want to put theirgears and rotors into the bodyin microsoopic machines forconducting experiments
Its like the movie innerSpace wilh Dennis Quaidsays researcher p~ OrmosThe machines could be builtso small that they would fitinto blood vessels for analyz-ing blood
To create the gears androtors Onnos uses hardenedliquid photopolymer Butunlike the micropans and their
pos ible lise the material isntnearly as exotic
Dentists use it a letann os says The material isthe same as whats II ed fortooth fillings hardened withultraviolet light
Ormes developed the tech-nique with Fewr Galajda in alittle more than a year--Just now weare perfectingit Ormes acids that hed likero use the technique in lessthan a year to build everaltypes of machine
Willi a doctorate ill phys-ics Ormos belongs to theHungarian Academy of Sci-ences and works at itsBiological Research Centrelocated in Szeged Ormos isdirector of the centres Insti-tnte of Biophy it Galajda istis doctoral snrdent
We study thephysics of
Created undBr II microscope threll rotan appear in front of the Dak-likeIJIIJ1Jc lif bullbullbull II 110mB n bairLivingsystems Ormes says Ormos and Galajdas gearsHe acids lliat theres a strong and rotors could be usedjndrive ill biology toward minia- that study as parts in micro-turizing which has a lot of scopic biochemical device promise in it The micromachines would be
bull accuracybull reliabilitybull maintolinCibilitybull Hexibilily performancebull and life cyde eest
AI Klingelnberg the point ofprecision is 10 help you controlyour gear manufocturing pro-cess and improve gearqudlitywith measuring systems thaIare benchmarks for
Klingelnberg measuringtechnology contaeLiebherr Gear Technology Co1465 Woodland DriveSaline MI4B 176-1259
_------------REVOLUTIONS------------_used ro investigate living sys-terns at a cellular level per-mitting the movement of indi-vidual ceIls-even individuallarge molecules Ormos says~ts a very precise tool thatcan be used in biology
With such machines scien-tists could introduce chemi-cals into cells manipulatetheir reactions and maintainthose cells environmentspumping different solutions todifferent regions They couldmeasure cell properties toselect certaia cells create achannel for transporting thosecells and transport the cellsindividually They could alsoremove compounds fromcells even destroy cells
The gears and rotors diam-eters can be as small as twomicrons A human hales diam-eter is about 100 microns At
two microns the parts canweigh as little as ]()LO grams
Ormos and GaIajda maketheir microparts by placingliquid photopolymer under amicroscope then moving acomputer-controlled laser fo-cus into the microscopeWhereverthe focus movesthe liquid becomes hardenedIf it moves in a gear shape thefocus makes a hardened gear
We can create a three-dimensionalobject that is ascomplicated as we wantOrmes says
DUI theres a wri nkle inthe technology that needs tobe ironed out
The micro gears are rotatedby the microrotors The micro-rotors are rotated by light
Its not easy to introducelight into the blood vesselsOmms says
But he adds there may be asolution to that problemOrmos explains that themachines in the body could bepowered by tightlfit wereintroduced effectively-via athin optic fiber for example
In similar research SandiaNational Laboratories in NewMexico has used chemicalmiddotelching to create microgearsand experimental micro-engines electric motors no
1 larger than a grain of sandOrmos started his research
j to understand how light causesI different trapped particles toj rotate But he later realizedi such light-induced rotationi could have useful applicationsI
1 It was not really the areaI
1 in which we were deliberately
II
moving he saysOnnos is unsure about the
techniques future-Whether
this can be commercialized ornot isnt clear Still he andOalajda are testing resins todecide which works best forcreating their gears and rotors
I think the possibilities arereally uolimited Ormes saysAnything that can be donewith larger machines can bedone with smaller ones too
Cirde302
Tbullbull V
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~
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Phone + 1-734-429-7225Fax 1-734-429-2294wwwpointofprecisioncominfopointofprecisioncom
bull 1INDUSTRV NEWS _
Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
S86 HilliardStreet RO Box 1898 Manchester CT06045-1898 USATelephone 86() 1649-0000 bull Fax 860 645-629g
Home Page httpwwwpurdytransmissionscomf-Mail salespurrlytransmissonsfOffl
Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
Fifty years or VARI-ROLL applications providebull Production Composite Inspectionbull Custom Design amp Build Part Gear Mounting Fixturesbull Standard Mounting Fixtures - Spurs Helicals Pinion Shafts
Worms Throated Worms Bevels Internals
When coupled with the VARI-PC Composite Gear AnalysisSystem will providebull Reduced Inspection Cost Improved Accuracy Historical Record Keepingbull Serialization of Partsbull Interface to SPC programsExperience the difference See why customers worldwide havechosen the VARI-ROLUVARImiddotPC For further informationplease contact us
Precision Gage ce Inc100 Shore Drive Burr Ridge IL 60521
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United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
CIRCLE 1Ji
ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
Will YoI TIIiIk bullbullIf you found 1his column of inbaIt lIIdIoruseful pIe
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16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
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Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
far __ illfonnalion eIIouI bull prIIIiucI DIIHrYiCJ JdHftIMd Ii hil iUIIII IIf 6_rfthohlfr I~-IM appropriate IIIUIIIber IIIIM lIIdr IInpg_ Callli MIlput ilia clrd in Ihe lIIIiI
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IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
AIW Sy5lcmsAero Gar [nc
AGMAAja M~ Corp
AmmCllll MeIlll T~1l Co
Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
1_1 I)CiuIG~tIJ TlaquohnoIDV
Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
TIle Gleason WollksHolroyd
lndex Technologies lee
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lnsco Corplnterstate Tool CorpTW H~ltIlandKim ~lnberg S(IIme GmbHKprOf AlneriQ LLCKoro Sluupening ServiceKrei~r~hleCoonl Ine
Mew Media loeb amp More
MiCroGCATMidwest Gear amp Tool IncMidWeIgtlGeM Corp
acbil Mrchjning Techno[ogy Co
iagllIll Gear Corp
Nona Gear Failure Semiruur
On-Iine ServIlCS Inc
Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
Profile Engmccnog IncPru-Oew Co locThe Purdy Corp
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GROUND GEARS- TeD or ren lhousandFor small to medium Quantities of spurs or helicals that have tomeet close-tolerance AGMA or DIN specs our Relshauer grindersand MampM gear analysis systems arelhe perfect combination
For Long runs we Offer the unique lIebherr CBN grindingprecess with full SPC Quality cOrtroland documentation
So whetller your needs are for lel1 or tens 01 thousands weinvite you to join the growing lst DIINSCO customers who rely onus lor consistent qua Irty reasonable costs and reliable delive ry
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ORPORATION
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weigh up to70 less thana comparable
steel arborFeather lighthydraulicarbors can bemanufactured wilhrunout as low as2 microns The clampingsleeves are replaceabte Thistoolingl is suitable for measuringtesting balancinggear grindingand other applications
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An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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If you would like more information abouta-tllo Bear CO circle1fUATA Geelllld circ _00 Drive a Gear Ltd clrcl aU-If you would like to respond to this or any other articlein this edition of GeBr Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-6618
A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
T Us YOII Think If you found this article of interest andor usefulplease circle aMIf you did not care for this article circle ~
If you would like more information about Pialllurgh ccirc ~If you would like to respond to this or any other articlein this edition of Gear Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-661 B
WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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(4a)
(4b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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SPIRAL BEVEL GEARS~Transmissions~
Spiral amp Straight BevellGear ManufBctulngCommercial to aircraft quaiity gearing
Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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Provides actual overballpin measurmenof any helical orgear or splin WiLU t-
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wwwgeartechnologeJlpocomwpowerrtatlamfsslotlcom WWWg9Iut9chnoloflycom GEAR TECHNOLOGYmiddot MAYIJUNIE 2001 45
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
REVOLUTIONS -- _
Hlarmonic ConceptsJazz lp
Planetary DesiglnIn the world of planetary
servo drives precision iseverything Advertisementsabound fOJ ervo gear driveswith extremely low or evenzere backlash With that typeof drive in high demand man-ufacturers have done every-thing they can to tighten theirdesigns-thmugh more exact-ing tolerances tighter assem-bly and better materials
Instead of tightening onemanufacturer of planetaryservo drives has tried loosen-
mg in order [0 provide the lowbacklash that manufacturers ofrobotics and other precise posi-
tioning equipment requireThat loosening bas nothing
te do with the manufacturingtolerances or assembly Pre-cision manufacturing is stillrequired Ithas to do with atype of flexibility borrowedfrom a related technologyharmonic drive gearing
Harmonic drive gearinghas long been known for itslow backlash high precisionand compact design Har-monic drive systems use a cir-cular spline a flex spline and
Cut-away view of the HPG gear drive from HIl Systems
me HPG drive includes II 11111 lIear 10 cantro bacldash(defoRnltion 8xallllerated for mustrative purposes
wavegenera~or to createextremely high ratios in a sin-gle reduction One of theadvantages of the harmonicdrive system is that the flexspline deforms as it rotates tokeep its teeth fully loadedagainst the circular spline alaU times
Engineers at HD Systems ofHauppauge NY haveliguredout how to apply the deforma-tion concept of harmonic drivesystems to planetary gears aswell Instead of a flexible imlerspline bull the HPG harmonicplanetary gearheads use aflexible outer ring gear to pre-load the gearset
The flexible outer ringgear of the HPG gearheadcreates a continually adju l-ing backlash compensationmethod The ring gear is thin-ner in the radial directionthan a typical ring gear Thismakes it radjaUy flexible yettorsionally stiff says HDSystems marketing managerBrian St Denis As normal
Wecome to Revolu-
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nd technology of thegell industry Revolu-
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gear wear occurs any in-crease in space between the
jteeth is immediately compen- Isated by the preload in the ring gear The concept is as if Ithe ring gear is a spring in the Iradial direction
The system employed byHD Systems has a huge advan-tage over those commonlyemployed by other maaufac-turers says St Denis Thebackla h of the HPG drivewont deteriorate over time
One method commonlyemployed toprovide low orzero backlash ill planetarygear systems is to create atight fit between all of thegears However this methodis subject to gear tooth wearand over the life of the gear-box the backl3sll can increasesignificantly
Another method is to usepreloaded bevel gears as panof the mechanism Shimsforce the bevel gears togetheraxially which forces a raclialpreload in the planetary gearsBacklash in this type of sys-tem also increases over timebecause of gear tooth wear
Because of the flexibledefermation of the planetaryring gear the HPG gearheadautomaucally compensatesfor gear tooth wear 81 Dellisays This helps ensure con-sistent backlash throughoutthe rated life of the gearbox
The H~ Series planetarygearheads have standardbacklash of less than 3 arc-minutes and they can beordered with 1 arc-minute ofbacklash as an option Theyare available in ratios from51 to 331
Cirele3mwwwpow9rrsnsmlssloncom bull wwwge8rtechnQJoycom bull GEAR TECHNOLOGYmiddotmiddot MAYJUNE 2001
MicmgearsFor Use In Tlhe
IHuman MachineIn a Hungarian lab using a
microscopes laser research-ers are creating gears androtors thinner than a humanhair ADd willie hair growsout of the body the re-searchers want to put theirgears and rotors into the bodyin microsoopic machines forconducting experiments
Its like the movie innerSpace wilh Dennis Quaidsays researcher p~ OrmosThe machines could be builtso small that they would fitinto blood vessels for analyz-ing blood
To create the gears androtors Onnos uses hardenedliquid photopolymer Butunlike the micropans and their
pos ible lise the material isntnearly as exotic
Dentists use it a letann os says The material isthe same as whats II ed fortooth fillings hardened withultraviolet light
Ormes developed the tech-nique with Fewr Galajda in alittle more than a year--Just now weare perfectingit Ormes acids that hed likero use the technique in lessthan a year to build everaltypes of machine
Willi a doctorate ill phys-ics Ormos belongs to theHungarian Academy of Sci-ences and works at itsBiological Research Centrelocated in Szeged Ormos isdirector of the centres Insti-tnte of Biophy it Galajda istis doctoral snrdent
We study thephysics of
Created undBr II microscope threll rotan appear in front of the Dak-likeIJIIJ1Jc lif bullbullbull II 110mB n bairLivingsystems Ormes says Ormos and Galajdas gearsHe acids lliat theres a strong and rotors could be usedjndrive ill biology toward minia- that study as parts in micro-turizing which has a lot of scopic biochemical device promise in it The micromachines would be
bull accuracybull reliabilitybull maintolinCibilitybull Hexibilily performancebull and life cyde eest
AI Klingelnberg the point ofprecision is 10 help you controlyour gear manufocturing pro-cess and improve gearqudlitywith measuring systems thaIare benchmarks for
Klingelnberg measuringtechnology contaeLiebherr Gear Technology Co1465 Woodland DriveSaline MI4B 176-1259
_------------REVOLUTIONS------------_used ro investigate living sys-terns at a cellular level per-mitting the movement of indi-vidual ceIls-even individuallarge molecules Ormos says~ts a very precise tool thatcan be used in biology
With such machines scien-tists could introduce chemi-cals into cells manipulatetheir reactions and maintainthose cells environmentspumping different solutions todifferent regions They couldmeasure cell properties toselect certaia cells create achannel for transporting thosecells and transport the cellsindividually They could alsoremove compounds fromcells even destroy cells
The gears and rotors diam-eters can be as small as twomicrons A human hales diam-eter is about 100 microns At
two microns the parts canweigh as little as ]()LO grams
Ormos and GaIajda maketheir microparts by placingliquid photopolymer under amicroscope then moving acomputer-controlled laser fo-cus into the microscopeWhereverthe focus movesthe liquid becomes hardenedIf it moves in a gear shape thefocus makes a hardened gear
We can create a three-dimensionalobject that is ascomplicated as we wantOrmes says
DUI theres a wri nkle inthe technology that needs tobe ironed out
The micro gears are rotatedby the microrotors The micro-rotors are rotated by light
Its not easy to introducelight into the blood vesselsOmms says
But he adds there may be asolution to that problemOrmos explains that themachines in the body could bepowered by tightlfit wereintroduced effectively-via athin optic fiber for example
In similar research SandiaNational Laboratories in NewMexico has used chemicalmiddotelching to create microgearsand experimental micro-engines electric motors no
1 larger than a grain of sandOrmos started his research
j to understand how light causesI different trapped particles toj rotate But he later realizedi such light-induced rotationi could have useful applicationsI
1 It was not really the areaI
1 in which we were deliberately
II
moving he saysOnnos is unsure about the
techniques future-Whether
this can be commercialized ornot isnt clear Still he andOalajda are testing resins todecide which works best forcreating their gears and rotors
I think the possibilities arereally uolimited Ormes saysAnything that can be donewith larger machines can bedone with smaller ones too
Cirde302
Tbullbull V
If you found tIriI IfticfI ofinterest andor UIefuI
~
l1~~
Phone + 1-734-429-7225Fax 1-734-429-2294wwwpointofprecisioncominfopointofprecisioncom
bull 1INDUSTRV NEWS _
Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
S86 HilliardStreet RO Box 1898 Manchester CT06045-1898 USATelephone 86() 1649-0000 bull Fax 860 645-629g
Home Page httpwwwpurdytransmissionscomf-Mail salespurrlytransmissonsfOffl
Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
Fifty years or VARI-ROLL applications providebull Production Composite Inspectionbull Custom Design amp Build Part Gear Mounting Fixturesbull Standard Mounting Fixtures - Spurs Helicals Pinion Shafts
Worms Throated Worms Bevels Internals
When coupled with the VARI-PC Composite Gear AnalysisSystem will providebull Reduced Inspection Cost Improved Accuracy Historical Record Keepingbull Serialization of Partsbull Interface to SPC programsExperience the difference See why customers worldwide havechosen the VARI-ROLUVARImiddotPC For further informationplease contact us
Precision Gage ce Inc100 Shore Drive Burr Ridge IL 60521
630-655-2121 Fax630-6S5-3073wwwpredsiongagecocom
United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
CIRCLE 1Ji
ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
Will YoI TIIiIk bullbullIf you found 1his column of inbaIt lIIdIoruseful pIe
If did notcn forflll coIumn _
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16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
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Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
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IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
AIW Sy5lcmsAero Gar [nc
AGMAAja M~ Corp
AmmCllll MeIlll T~1l Co
Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
1_1 I)CiuIG~tIJ TlaquohnoIDV
Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
TIle Gleason WollksHolroyd
lndex Technologies lee
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lnsco Corplnterstate Tool CorpTW H~ltIlandKim ~lnberg S(IIme GmbHKprOf AlneriQ LLCKoro Sluupening ServiceKrei~r~hleCoonl Ine
Mew Media loeb amp More
MiCroGCATMidwest Gear amp Tool IncMidWeIgtlGeM Corp
acbil Mrchjning Techno[ogy Co
iagllIll Gear Corp
Nona Gear Failure Semiruur
On-Iine ServIlCS Inc
Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
Profile Engmccnog IncPru-Oew Co locThe Purdy Corp
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GROUND GEARS- TeD or ren lhousandFor small to medium Quantities of spurs or helicals that have tomeet close-tolerance AGMA or DIN specs our Relshauer grindersand MampM gear analysis systems arelhe perfect combination
For Long runs we Offer the unique lIebherr CBN grindingprecess with full SPC Quality cOrtroland documentation
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TooHnk Engineeringoffers hydraulic arbors
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weigh up to70 less thana comparable
steel arborFeather lighthydraulicarbors can bemanufactured wilhrunout as low as2 microns The clampingsleeves are replaceabte Thistoolingl is suitable for measuringtesting balancinggear grindingand other applications
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An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
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WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
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AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
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May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
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THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
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D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
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_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
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Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
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New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
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and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
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New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
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INACHIIMACHININGTECHNOLOGY CO
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CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
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NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
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HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
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RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
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CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
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Direct your inquiries toRon lfIumphrerGeneral Manage
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1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
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IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
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GEAR TOOTHGRINDING SERV~CES
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HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
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Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
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bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
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Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
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PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
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HSS amp Carbide up to 5 DiaStraight Gash
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GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
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bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
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Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
MicmgearsFor Use In Tlhe
IHuman MachineIn a Hungarian lab using a
microscopes laser research-ers are creating gears androtors thinner than a humanhair ADd willie hair growsout of the body the re-searchers want to put theirgears and rotors into the bodyin microsoopic machines forconducting experiments
Its like the movie innerSpace wilh Dennis Quaidsays researcher p~ OrmosThe machines could be builtso small that they would fitinto blood vessels for analyz-ing blood
To create the gears androtors Onnos uses hardenedliquid photopolymer Butunlike the micropans and their
pos ible lise the material isntnearly as exotic
Dentists use it a letann os says The material isthe same as whats II ed fortooth fillings hardened withultraviolet light
Ormes developed the tech-nique with Fewr Galajda in alittle more than a year--Just now weare perfectingit Ormes acids that hed likero use the technique in lessthan a year to build everaltypes of machine
Willi a doctorate ill phys-ics Ormos belongs to theHungarian Academy of Sci-ences and works at itsBiological Research Centrelocated in Szeged Ormos isdirector of the centres Insti-tnte of Biophy it Galajda istis doctoral snrdent
We study thephysics of
Created undBr II microscope threll rotan appear in front of the Dak-likeIJIIJ1Jc lif bullbullbull II 110mB n bairLivingsystems Ormes says Ormos and Galajdas gearsHe acids lliat theres a strong and rotors could be usedjndrive ill biology toward minia- that study as parts in micro-turizing which has a lot of scopic biochemical device promise in it The micromachines would be
bull accuracybull reliabilitybull maintolinCibilitybull Hexibilily performancebull and life cyde eest
AI Klingelnberg the point ofprecision is 10 help you controlyour gear manufocturing pro-cess and improve gearqudlitywith measuring systems thaIare benchmarks for
Klingelnberg measuringtechnology contaeLiebherr Gear Technology Co1465 Woodland DriveSaline MI4B 176-1259
_------------REVOLUTIONS------------_used ro investigate living sys-terns at a cellular level per-mitting the movement of indi-vidual ceIls-even individuallarge molecules Ormos says~ts a very precise tool thatcan be used in biology
With such machines scien-tists could introduce chemi-cals into cells manipulatetheir reactions and maintainthose cells environmentspumping different solutions todifferent regions They couldmeasure cell properties toselect certaia cells create achannel for transporting thosecells and transport the cellsindividually They could alsoremove compounds fromcells even destroy cells
The gears and rotors diam-eters can be as small as twomicrons A human hales diam-eter is about 100 microns At
two microns the parts canweigh as little as ]()LO grams
Ormos and GaIajda maketheir microparts by placingliquid photopolymer under amicroscope then moving acomputer-controlled laser fo-cus into the microscopeWhereverthe focus movesthe liquid becomes hardenedIf it moves in a gear shape thefocus makes a hardened gear
We can create a three-dimensionalobject that is ascomplicated as we wantOrmes says
DUI theres a wri nkle inthe technology that needs tobe ironed out
The micro gears are rotatedby the microrotors The micro-rotors are rotated by light
Its not easy to introducelight into the blood vesselsOmms says
But he adds there may be asolution to that problemOrmos explains that themachines in the body could bepowered by tightlfit wereintroduced effectively-via athin optic fiber for example
In similar research SandiaNational Laboratories in NewMexico has used chemicalmiddotelching to create microgearsand experimental micro-engines electric motors no
1 larger than a grain of sandOrmos started his research
j to understand how light causesI different trapped particles toj rotate But he later realizedi such light-induced rotationi could have useful applicationsI
1 It was not really the areaI
1 in which we were deliberately
II
moving he saysOnnos is unsure about the
techniques future-Whether
this can be commercialized ornot isnt clear Still he andOalajda are testing resins todecide which works best forcreating their gears and rotors
I think the possibilities arereally uolimited Ormes saysAnything that can be donewith larger machines can bedone with smaller ones too
Cirde302
Tbullbull V
If you found tIriI IfticfI ofinterest andor UIefuI
~
l1~~
Phone + 1-734-429-7225Fax 1-734-429-2294wwwpointofprecisioncominfopointofprecisioncom
bull 1INDUSTRV NEWS _
Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
S86 HilliardStreet RO Box 1898 Manchester CT06045-1898 USATelephone 86() 1649-0000 bull Fax 860 645-629g
Home Page httpwwwpurdytransmissionscomf-Mail salespurrlytransmissonsfOffl
Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
Fifty years or VARI-ROLL applications providebull Production Composite Inspectionbull Custom Design amp Build Part Gear Mounting Fixturesbull Standard Mounting Fixtures - Spurs Helicals Pinion Shafts
Worms Throated Worms Bevels Internals
When coupled with the VARI-PC Composite Gear AnalysisSystem will providebull Reduced Inspection Cost Improved Accuracy Historical Record Keepingbull Serialization of Partsbull Interface to SPC programsExperience the difference See why customers worldwide havechosen the VARI-ROLUVARImiddotPC For further informationplease contact us
Precision Gage ce Inc100 Shore Drive Burr Ridge IL 60521
630-655-2121 Fax630-6S5-3073wwwpredsiongagecocom
United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
CIRCLE 1Ji
ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
Will YoI TIIiIk bullbullIf you found 1his column of inbaIt lIIdIoruseful pIe
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16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
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Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
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taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
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Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
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Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
Profile Engmccnog IncPru-Oew Co locThe Purdy Corp
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steel arborFeather lighthydraulicarbors can bemanufactured wilhrunout as low as2 microns The clampingsleeves are replaceabte Thistoolingl is suitable for measuringtesting balancinggear grindingand other applications
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An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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If you would like more information abouta-tllo Bear CO circle1fUATA Geelllld circ _00 Drive a Gear Ltd clrcl aU-If you would like to respond to this or any other articlein this edition of GeBr Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-6618
A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
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AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
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CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
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Fr ---i 0 C[ III I I
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Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
If you found this article of interest andoruseful pI sa circle
MAYJUNE 2001 bull GiEAR TECHNQlQGY wWlIgurechlloloQycom bull wwwpowerlrslIsmluloncom
GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
wwwpowIJrtrIJflsmissioncom wwwgearlmiddotschflologycom GEAR TECHNOLOGYmiddot MAYtJUNE 20Ql 43
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
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Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
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Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
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bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
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800-447middot2392Fa 71H74-t003
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PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
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GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
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bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
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4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
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Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
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Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
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Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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_------------REVOLUTIONS------------_used ro investigate living sys-terns at a cellular level per-mitting the movement of indi-vidual ceIls-even individuallarge molecules Ormos says~ts a very precise tool thatcan be used in biology
With such machines scien-tists could introduce chemi-cals into cells manipulatetheir reactions and maintainthose cells environmentspumping different solutions todifferent regions They couldmeasure cell properties toselect certaia cells create achannel for transporting thosecells and transport the cellsindividually They could alsoremove compounds fromcells even destroy cells
The gears and rotors diam-eters can be as small as twomicrons A human hales diam-eter is about 100 microns At
two microns the parts canweigh as little as ]()LO grams
Ormos and GaIajda maketheir microparts by placingliquid photopolymer under amicroscope then moving acomputer-controlled laser fo-cus into the microscopeWhereverthe focus movesthe liquid becomes hardenedIf it moves in a gear shape thefocus makes a hardened gear
We can create a three-dimensionalobject that is ascomplicated as we wantOrmes says
DUI theres a wri nkle inthe technology that needs tobe ironed out
The micro gears are rotatedby the microrotors The micro-rotors are rotated by light
Its not easy to introducelight into the blood vesselsOmms says
But he adds there may be asolution to that problemOrmos explains that themachines in the body could bepowered by tightlfit wereintroduced effectively-via athin optic fiber for example
In similar research SandiaNational Laboratories in NewMexico has used chemicalmiddotelching to create microgearsand experimental micro-engines electric motors no
1 larger than a grain of sandOrmos started his research
j to understand how light causesI different trapped particles toj rotate But he later realizedi such light-induced rotationi could have useful applicationsI
1 It was not really the areaI
1 in which we were deliberately
II
moving he saysOnnos is unsure about the
techniques future-Whether
this can be commercialized ornot isnt clear Still he andOalajda are testing resins todecide which works best forcreating their gears and rotors
I think the possibilities arereally uolimited Ormes saysAnything that can be donewith larger machines can bedone with smaller ones too
Cirde302
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If you found tIriI IfticfI ofinterest andor UIefuI
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Phone + 1-734-429-7225Fax 1-734-429-2294wwwpointofprecisioncominfopointofprecisioncom
bull 1INDUSTRV NEWS _
Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
S86 HilliardStreet RO Box 1898 Manchester CT06045-1898 USATelephone 86() 1649-0000 bull Fax 860 645-629g
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Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
Fifty years or VARI-ROLL applications providebull Production Composite Inspectionbull Custom Design amp Build Part Gear Mounting Fixturesbull Standard Mounting Fixtures - Spurs Helicals Pinion Shafts
Worms Throated Worms Bevels Internals
When coupled with the VARI-PC Composite Gear AnalysisSystem will providebull Reduced Inspection Cost Improved Accuracy Historical Record Keepingbull Serialization of Partsbull Interface to SPC programsExperience the difference See why customers worldwide havechosen the VARI-ROLUVARImiddotPC For further informationplease contact us
Precision Gage ce Inc100 Shore Drive Burr Ridge IL 60521
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United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
CIRCLE 1Ji
ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
Will YoI TIIiIk bullbullIf you found 1his column of inbaIt lIIdIoruseful pIe
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16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
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Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
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IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
AIW Sy5lcmsAero Gar [nc
AGMAAja M~ Corp
AmmCllll MeIlll T~1l Co
Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
1_1 I)CiuIG~tIJ TlaquohnoIDV
Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
TIle Gleason WollksHolroyd
lndex Technologies lee
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lnsco Corplnterstate Tool CorpTW H~ltIlandKim ~lnberg S(IIme GmbHKprOf AlneriQ LLCKoro Sluupening ServiceKrei~r~hleCoonl Ine
Mew Media loeb amp More
MiCroGCATMidwest Gear amp Tool IncMidWeIgtlGeM Corp
acbil Mrchjning Techno[ogy Co
iagllIll Gear Corp
Nona Gear Failure Semiruur
On-Iine ServIlCS Inc
Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
Profile Engmccnog IncPru-Oew Co locThe Purdy Corp
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GROUND GEARS- TeD or ren lhousandFor small to medium Quantities of spurs or helicals that have tomeet close-tolerance AGMA or DIN specs our Relshauer grindersand MampM gear analysis systems arelhe perfect combination
For Long runs we Offer the unique lIebherr CBN grindingprecess with full SPC Quality cOrtroland documentation
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ORPORATION
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steel arborFeather lighthydraulicarbors can bemanufactured wilhrunout as low as2 microns The clampingsleeves are replaceabte Thistoolingl is suitable for measuringtesting balancinggear grindingand other applications
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powrrrIIM$4IOIIcom gulchnologycom bull GEAR TECHNOLOGY bull MAYJUNE 2DDI U
An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
Tell Ua WIIeIYDII T1IiK
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If you would like more information abouta-tllo Bear CO circle1fUATA Geelllld circ _00 Drive a Gear Ltd clrcl aU-If you would like to respond to this or any other articlein this edition of GeBr Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-6618
A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
T Us YOII Think If you found this article of interest andor usefulplease circle aMIf you did not care for this article circle ~
If you would like more information about Pialllurgh ccirc ~If you would like to respond to this or any other articlein this edition of Gear Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-661 B
WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
Solutions for yourgear manufacturingneeds~owefiedbySamputensil
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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(4a)
(4b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
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_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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SPIRAL BEVEL GEARS~Transmissions~
Spiral amp Straight BevellGear ManufBctulngCommercial to aircraft quaiity gearing
Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
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June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
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NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
-
PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Regal-Beloit Buys Spiral Bevellune from Pbiladelphia GearRegal-Beloit corp has purchased the
piraJ bevel gear product line of thePhiladelphia Gear Co according taatarernent released earlier this year The
purchased assetsinclnded itnventmy andselected machinery equipment and tool-ing relating 10 the pLraI bevel gear line
OIfOlfOlfpoOlfOrnlmluoncom (I bullbull tlchnologycom GEAR TECHNOLOGY MAYJUNE 2001 15
AGMA IElects New OfficersThe American Gear Manufacturers
Assoeiation elected its 200]-2002officmiddotersat the associations annualmeeting in March The new officerswill help direct the organizationthrough March 2002
The newly elected officers are Chairman Arlin Peny president of
Comer Inc in Charlene NC Perry wasfonnerly pre id lit of Gear ProductsIncin Tul a OK
bull Vice Chai_rrrum Roger Pennycook vicepre ident of sales for Textron PowerTransmission North America in Trav-erse City Mm
bull Treasurer 1Cameron Drecoll presidentof Brad Foote Gear Works Inc inCicero [L
bull Cllainnan 01 the Administrative Divi-si(lfl Executive CommittEe Marlin Wood-nouse vice president of sales for StarCutter Co in Farmington Hills Ml
bull Chaimmn of the Technical Divi ion Ex-ecutive Committee David McCarthyvice president of engineering for DorrisCo Incm St Louis MO
Outgoing chairman Frederic MYoung president of Forest City Gear Coin Ro coe IL assumes the title of chair-man emerinu
IBn Shearingl Joins IMitsubishiIan Shearing has been
named vice president ofsale for the MitsubishiGear Technology Centerheadquartered in Wixom
11- ~ MI a Detroit uburbAccording to an announcement from
Thomas P Kelly the center presidentShearing will be responsible for all USand Canadiaa sale of tbecompanys tineof gear-cutting machine tool and cutters
The line with annual sales of about $4million includes design and manufactur-ing capabilitie for Klingelnberg bevelgearing The business will be moved toChicago to the fcote-Jonesllliecis Geardivision of Regal-Beloit
Derlan Acquires Wind orIGear amp D~ive
Derlan Industries Ltd a TomlllD-basedi
manufacturer ofproclucts for the 8J rospaceand pu_mp indusnies acquired ubstantiallyall the assets ofWmclsor Gear amp Drive Incof Windsor Ontario in March
Windsor Gear amp Drive manufacturegears and drive for aero pace and auto-motiveapplication The cquiitionhelps Derlan compete in tile com_modilysegment of the aerospace gear marketac-cording to a release issued by Derlan
THE PURDYCORPORATION
S86 HilliardStreet RO Box 1898 Manchester CT06045-1898 USATelephone 86() 1649-0000 bull Fax 860 645-629g
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Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
Yesterdays ReliabilityTomorrouis Tedmologu
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United Gear 81 Assembly AddsHleat1ireating Capacity
United Gear amp A embly Inc ofHudson WI has installed a large-capac-ity pusher furnace tocarburize quenchand temper gears and shafts The newfurnace has a capacity of 1000 lbshr
TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
bull ~~~NDUSTRYNEWSII _
companys facility in Frederick COForbes joined UQM after more than
35 years with Hamilton Srllldslrandwller~ he was most recently plant man-ager of the companys Denver manufac-turing facility Prior to that Forbes wasmanaging director of Sundstrand PacificAerospace located in Singapore Ham-ilton Sundstrand is a subsidiary ofUnited Technologies Corp
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ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
Will YoI TIIiIk bullbullIf you found 1his column of inbaIt lIIdIoruseful pIe
If did notcn forflll coIumn _
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If you would like to mpond to this or anyother article In tltil adlllon of 60rTMhntw=faxvour ~totheIIlIfIdon If SIDU manqlnt edIIur ItIMJ437-1818 or I8ftd melII1D ~com
16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
S- Amcricllinc
Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
far __ illfonnalion eIIouI bull prIIIiucI DIIHrYiCJ JdHftIMd Ii hil iUIIII IIf 6_rfthohlfr I~-IM appropriate IIIUIIIber IIIIM lIIdr IInpg_ Callli MIlput ilia clrd in Ihe lIIIiI
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IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
AIW Sy5lcmsAero Gar [nc
AGMAAja M~ Corp
AmmCllll MeIlll T~1l Co
Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
1_1 I)CiuIG~tIJ TlaquohnoIDV
Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
TIle Gleason WollksHolroyd
lndex Technologies lee
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lnsco Corplnterstate Tool CorpTW H~ltIlandKim ~lnberg S(IIme GmbHKprOf AlneriQ LLCKoro Sluupening ServiceKrei~r~hleCoonl Ine
Mew Media loeb amp More
MiCroGCATMidwest Gear amp Tool IncMidWeIgtlGeM Corp
acbil Mrchjning Techno[ogy Co
iagllIll Gear Corp
Nona Gear Failure Semiruur
On-Iine ServIlCS Inc
Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
Profile Engmccnog IncPru-Oew Co locThe Purdy Corp
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GROUND GEARS- TeD or ren lhousandFor small to medium Quantities of spurs or helicals that have tomeet close-tolerance AGMA or DIN specs our Relshauer grindersand MampM gear analysis systems arelhe perfect combination
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powrrrIIM$4IOIIcom gulchnologycom bull GEAR TECHNOLOGY bull MAYJUNE 2DDI U
An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
Tell Ua WIIeIYDII T1IiK
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If you would like more information abouta-tllo Bear CO circle1fUATA Geelllld circ _00 Drive a Gear Ltd clrcl aU-If you would like to respond to this or any other articlein this edition of GeBr Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-6618
A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
T Us YOII Think If you found this article of interest andor usefulplease circle aMIf you did not care for this article circle ~
If you would like more information about Pialllurgh ccirc ~If you would like to respond to this or any other articlein this edition of Gear Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-661 B
WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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SPIRAL BEVEL GEARS~Transmissions~
Spiral amp Straight BevellGear ManufBctulngCommercial to aircraft quaiity gearing
Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
I--+--+--t--~ T1RUE DIMENSION GEAR INmiddotSPEC
Provides actual overballpin measurmenof any helical orgear or splin WiLU t-
the need ofcostlysetting masters
Ga~ Division
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9 ODS ID
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851 OHIO PIKE middotCINCINNATI OHIO 45245 bull (513) 152-6000 bull FAX (513) 75205599
CIRCLIE 13jt
Learn mare at ShON Central
bull Exhlibiitor Liistbull Booth Descriptions
bull NEW THIS YIEAIR Online Videos
Plan our visit to tile sllow months in advainceat Shaw Central
wwwgeartechnologeJlpocomwpowerrtatlamfsslotlcom WWWg9Iut9chnoloflycom GEAR TECHNOLOGYmiddot MAYIJUNIE 2001 45
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
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ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
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Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Gary L IForbes Appointed GM otUoM Power Products
UQM Technologies Inc (formerlyUnique Mobility lllc)a developer ofalternative energy technologies inGolden CO named Gary L Forbes asgeneral manager of its UQM PowerProducts unit in January The PowerProducts unir manufactures gears gear-boxes and brushless DC motors at the
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United Gear 81 Assembly AddsHleat1ireating Capacity
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TIle system bas been integrated intoUnited Gear amp Assemblys manufactur-ing operations so high-volume compo-nents can move right from manufactur-ing cells to the furnace and directly intopress quenching accordiinglO a state-ment released bylhe oompany
United Gear amp Assembly manufae-rures gears shafts and assemblies for theautomotive agriculture construction andmarine markets
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ASME Codes and StandardsAvaHable Online
The ASME Digital Store whichopened in March allows engineers tobrowse and obtain electronic versions ofASMEs codes and standards via thesocietys Website at wwwasmeorg
The online store include electronicfiles of 400 ASME [publications includ-ing codes and standards for tools fasten-ers flow measurement pumps turbinesdimensioning and toleraneiag as well asother categories Visilors can search thestores database by keyword or categofY
fairfield IExpandstOI IndiaFairfield Manufacturing Co Inc ofLafayette IN acquired Atlas Gear Ltdin October
Located just outside Belgaum IndiaAtlas Gear is a major supplier of gearsfor agriculturaland off-road vehicles inhe Indian market The division win beknown as Fairfield Atlas Ltd 0
Will YoI TIIiIk bullbullIf you found 1his column of inbaIt lIIdIoruseful pIe
If did notcn forflll coIumn _
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If you would like to mpond to this or anyother article In tltil adlllon of 60rTMhntw=faxvour ~totheIIlIfIdon If SIDU manqlnt edIIur ItIMJ437-1818 or I8ftd melII1D ~com
16 MAYJUNE 2001 bull GEAR TECHNOLOGY wgurhnolol1yrom bull 1I1I1IpOIIrlrllI~mlulollcom
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Tool ink EngineeringT ran tllllltiC Connection IncUnited Tool Supply
far __ illfonnalion eIIouI bull prIIIiucI DIIHrYiCJ JdHftIMd Ii hil iUIIII IIf 6_rfthohlfr I~-IM appropriate IIIUIIIber IIIIM lIIdr IInpg_ Callli MIlput ilia clrd in Ihe lIIIiI
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IIEAtIER PAGEAJlVER1lSER SERVICE NUMBER NUMBER
taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
AIW Sy5lcmsAero Gar [nc
AGMAAja M~ Corp
AmmCllll MeIlll T~1l Co
Applied Pmctss lee
BWllnlc1lJmni ospBlaquoker Gearmeisrers IncBodine GCl M1yrlClurin~
Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
1_1 I)CiuIG~tIJ TlaquohnoIDV
Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
TIle Gleason WollksHolroyd
lndex Technologies lee
Inducloheai
lnsco Corplnterstate Tool CorpTW H~ltIlandKim ~lnberg S(IIme GmbHKprOf AlneriQ LLCKoro Sluupening ServiceKrei~r~hleCoonl Ine
Mew Media loeb amp More
MiCroGCATMidwest Gear amp Tool IncMidWeIgtlGeM Corp
acbil Mrchjning Techno[ogy Co
iagllIll Gear Corp
Nona Gear Failure Semiruur
On-Iine ServIlCS Inc
Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
Profile Engmccnog IncPru-Oew Co locThe Purdy Corp
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An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
Tell Ua WIIeIYDII T1IiK
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If you would like more information abouta-tllo Bear CO circle1fUATA Geelllld circ _00 Drive a Gear Ltd clrcl aU-If you would like to respond to this or any other articlein this edition of GeBr Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-6618
A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
T Us YOII Think If you found this article of interest andor usefulplease circle aMIf you did not care for this article circle ~
If you would like more information about Pialllurgh ccirc ~If you would like to respond to this or any other articlein this edition of Gear Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-661 B
WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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Aero Gear Inc~050Drt lUllRd Wllldor CT IDIiImltTel (860) 6880888IFax 1860) 285-3514
emsll buygsarsiaerogearcom bull wwwaerogearcoml
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
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static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
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Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
I--+--+--t--~ T1RUE DIMENSION GEAR INmiddotSPEC
Provides actual overballpin measurmenof any helical orgear or splin WiLU t-
the need ofcostlysetting masters
Ga~ Division
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851 OHIO PIKE middotCINCINNATI OHIO 45245 bull (513) 152-6000 bull FAX (513) 75205599
CIRCLIE 13jt
Learn mare at ShON Central
bull Exhlibiitor Liistbull Booth Descriptions
bull NEW THIS YIEAIR Online Videos
Plan our visit to tile sllow months in advainceat Shaw Central
wwwgeartechnologeJlpocomwpowerrtatlamfsslotlcom WWWg9Iut9chnoloflycom GEAR TECHNOLOGYmiddot MAYIJUNIE 2001 45
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
I till Us DIIIk
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
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taycar Gear amp Machine Co 177
Shovol CllJlruJ 0Ilb ampr lWsry Home Page 290Slar Cllller Co 128164
AIW Sy5lcmsAero Gar [nc
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AmmCllll MeIlll T~1l Co
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Bourn Koch Machine Tool Co
The Cincinnarl Gear Co
Crown Power Train srIDr Kaiser (Sl MUfSQII)DuramiddotBMFairfield M1ufacluring Co Inc
Flluler Corp
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Gear T~dfllolgy Cl)ROt ByeS GuikGear Tcchnology eenler
Div of MIlgtubhi ll~mational CorpGle on CUlling Tools Corp
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On-Iine ServIlCS Inc
Parker InduiltlC IncPerl) Tecbn logy Corp[HJW~ronsmLujOllcomPrecision age o Inc
PnmIC CorpProc IEquiprIl(Cot Co
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An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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If you would like more information abouta-tllo Bear CO circle1fUATA Geelllld circ _00 Drive a Gear Ltd clrcl aU-If you would like to respond to this or any other articlein this edition of GeBr Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-6618
A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
T Us YOII Think If you found this article of interest andor usefulplease circle aMIf you did not care for this article circle ~
If you would like more information about Pialllurgh ccirc ~If you would like to respond to this or any other articlein this edition of Gear Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-661 B
WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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(4a)
(4b)
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(5b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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SPIRAL BEVEL GEARS~Transmissions~
Spiral amp Straight BevellGear ManufBctulngCommercial to aircraft quaiity gearing
Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
I--+--+--t--~ T1RUE DIMENSION GEAR INmiddotSPEC
Provides actual overballpin measurmenof any helical orgear or splin WiLU t-
the need ofcostlysetting masters
Ga~ Division
d Tool _I
9 ODS ID
I
851 OHIO PIKE middotCINCINNATI OHIO 45245 bull (513) 152-6000 bull FAX (513) 75205599
CIRCLIE 13jt
Learn mare at ShON Central
bull Exhlibiitor Liistbull Booth Descriptions
bull NEW THIS YIEAIR Online Videos
Plan our visit to tile sllow months in advainceat Shaw Central
wwwgeartechnologeJlpocomwpowerrtatlamfsslotlcom WWWg9Iut9chnoloflycom GEAR TECHNOLOGYmiddot MAYIJUNIE 2001 45
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
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PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
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HOB SHARPENINGSERVICE
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
An employ of ATA IGIIII Iltdworks on one of th eomplnylwlllr llltbiMl nil lurbinesL S1IJI11y_d tRlrgy-pro-dgcilfgl comlnill -_ priYIIICOlIIJlni Ihll own rivtrIIIpilh
Taking On NatureThree Gear Companies
And Their End- ProductsJoseph l Hazelton
Many gear companies male parts buildassemblies and stoptliere But some dontstop rJtey go a step further and createend-prod-uets Three gear companies have taken that stepand taken on nature with their creations
Ontario Drive amp Gear rides across land andwater with itsamphibious vehicles ATA Gearfunnels water through it turbines for electrici-ty Amarillo Gear raisestemperatures truoughits wind machines
Finding Theiir NichesAmarillo Gear Started in 1917 Amarillo
Gear Co of Amarillo TX manufactures spiral-bevel right-angle gear drives and fan drivesThe gear drives are used for agricultural pumpsbow thrusters for docking ships cooling towerfMS drilling rotary table gears fire contrclflood control sewage treatment plants andwater desalination plants
In 1934llle company started building andservicinggearboxes in agricultural applications
In [974 it turned its expertise to upper aJldlower gearboxes for wind machines
Years later Amarillo Gear used irs know-how to develop whole wind machines In 1989the company formed Amarillo Wind MachineCo
Located in Exeter CA Amarillo Wind man-ufacrures and services wiad machines used toprotect crops susceptible to ftost with a rela-tively high value per acre The crop includeavocados cherries flowers strawberries andcitrus fruits like grapefruits lemon andoranges
ATA Ge~lrS Started in 1937 ATA Gears Ltdof Tarnpere Finland manufactures spiral bevelgears and custom-made gearboxes The partsand assemblies are for machines thai handleheavy or shock loads and operate in extremetemperatures or dusty environments
ATA Gears spiral bevel gears are in its waterturbines Pentti Hallila general manager ofsales and technical services say the companystarted rna_king water turbisesto extend Lboegears to an end-product
The turbines are usually provided to energy-producing companies and private companiesthat own river rapids Hallila say 3 companybuys a turbine if it happens to be 011 a river andwants to make electricity from it He adds thatbu inesses may be in very remote place wherethey cant get electricity from a public network
Ontario Drive amp Gear Started in 1962Ontario Drive amp Gear Ltd (GOG) developedand manufactured a special transmission for asix-wheel-drive amphibious all-terrain vehicle
They were looking for a stable market fortheir products says Michael Eckardt ODGsvice president of finance
In 1967 the company entered the marketwith its own amplnbious vehlele bull called Argos
ocated in New Hamburg Ontario Canada18 MAYtJUNE 2001 bull GEAR TECHNOLOGY _gesrlechnoloflY cQm bull wp transmlssloneom
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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If you would like more information abouta-tllo Bear CO circle1fUATA Geelllld circ _00 Drive a Gear Ltd clrcl aU-If you would like to respond to this or any other articlein this edition of GeBr Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-6618
A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
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AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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Spiral amp Straight BevellGear ManufBctulngCommercial to aircraft quaiity gearing
Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
MIIlWist GEARamp TOIl IINC
ICONTACTCRAIGi D RIISS(B10) 754middot8923
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
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Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
If you found this article of interest andoruseful pI sa circle
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
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Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
-
PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
aDO manufactures sporvhelical internal andworm gears It also manufactures spur helicaland worm gearboxes Meanwhile its amphibi-ous vehicles use helicel and spur gears Theparts and assemblies are used in agricultureautomation material-handling mobile liftequipment municipal tractors and transporta-tion
The vehicles are used for disaster responseemergency medical service search and rescueresource exploration and recreation-like hunt-ing and fishing
And anything else where you have to be offthe beaten track Eckardt says
Tile Macbines In Their NichesAmarillo Gear Amarillo Gears spiral bevel
gears are in AmariUo Winds machinesAmarillo Wind receives the gears assembles theengines then creates their frames andthe windmachines towers
Each machine has two sets of spiral bevelgears one set in the lower gearbox one in theupper gearbox The lower box receives powerfrom the engine and sends it up the pipes driveline to the upper box which is connected to thefan blade
Also each machine has a set of worm-and-worm-whee] reduction gears allowing the uppergearbox-s-and the blade-to 1I0taW3600 aroundthe tower
As an example the standard machine fer cit-rus crops is about 3S feet tall from the ground tothe blades center-tall enough to clear treetopsThe blade is ]8 feet long
Tilted 60 down the blade draws warm airfrom above from the inversion layer and blowsit down on the trees raising the temperature atground level to protect the crops from frost
A machine is placed mthe center of every Wacres of citrus trees in an orchard To affect alll() acres the machine blows air at nearly 30mph
It stirs the air quite a lot says Roger HeinAmarillo Winds general manager
The wind machines cant hold nature at bayAs Hein says they dont prevent all frost buttheyaUow farmers to change Mother Nature bya few degrees
Those few degrees can make tile differencethough
For example Americas largest orchards foreating oranges are in southern California in theCentral Valley Despite its warm climateCalifornia can have freezing temperatures inNovember and December
The best temperatures for growing orangesrange from a high of 95deg to a low of about 30deg
I At about 27deg oranges can start to have prob-lems says farm manager Edward Lorenzi of SunPacific Located in Bakersfield CA Sun Pacificgrows citrus fruits in the Central Valley and usesmachines from Amarillo Wind
The oranges problems are dissipation oftheir juice and damage to their appearance
Oranges have small cells that hold their juiceIf the temperature is too [ow theoranges freezeand the frozen juice breaks through the cellsWhen the oranges later thaw their juice evapo-rates Also California eating oranges must lookappetizing-no wind scars no fungus
Once damaged the eating oranges would beused for any remaining juice Their value wouldbe limited to their juice value
The difference between a fresh marketorange and a juice orange in California is thedifference between making money and losingmoney Lorenzi says
He explains that depending on the marketeating oranges of export quality can sell for asmuch as $14 per carton As for a carton of eat-ing oranges used for juice You mighl be ableto gel $4
Each wind machine usuaUy rues about 100hour during winter and protects probably$20000--$30bull000 in citrus fruit As a farm man-ager Lorenzi himself is responsible for 3000acres of citrus fruits
AI Impkly of Oitlfio Orin ItGllr Udl Iblnd av-r I ArgoIIplliblaul nblel ani I IIIDmbly lillll DOG Impbibl-OUI YlIbJelll Irt Ibuilt In NlwH m u7g Ontario CI dl
J10seph L Hazeltonis associate editor ofGear Technology Trainedin journalism hI WQS areporter for two wtlkJy
newspapers in MichigO1before joining GearTechnologys slqff
pottlnsmiuiollcommiddot wwwg9I1rrechllolmiddotogycom bull GEAR TECHNOLOGY bull MAYJUNE2001 9
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
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WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
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For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
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Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
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and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
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COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
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HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
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AUSTEMPERINGIMIPROViES MATERIAL
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NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
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SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
Made by Amarillo Wind IMachine Co a wind machine lor citrus crops can protect 10 acres of Iraes bylblowing higher warmer air down onlhem lIhemachines blow he air at almost 30 mph
Euch ala wind maehines gearbOIllS incld8l1 set olspi11 bevel gears as in this cress sectioD AmarilloWind gels hose gears rom its parenl complny Ama~ilIo GeM Co
A standard machine from Amarillo Windcosts $15000-$20000
ATA Gears ATA Gears water turbines createelectrical energy from flowing water The tur-bines power depends all the waters netheadand flow volume The turbine usually needwater with a head of 6-70 feet flowing at a rateof 30-] 800 cubic feet per second
Depending on those factors the turbinesusually generate 20-2500 kilowatts
To generate their power the turbines must bepart of a dam When the dam i opened waterflows through the turbine and rotates the runnerblades driving the shafts and spiral bevel gearthat power the generator
Hallila explains a water turbines costdepends on size and conditions but its roughly$1000 per rated kilowatt Also there may beadditional costs for other items like the dam
~Ontarjo Drive amp Gear The Argos are small
J-vehicles that look like rugged open automo-biles Depending om the model they have sixwheels and can carry four people or have eightwheels andcan carry six people They have 16-hp to 20-hp engines and bodies made of poly-ethylene a type of plastic Tneall-wheel-oriveArgos can travel at 20-22 mph
Weighing 765-1025 pounds the vehiclesmight not be expected to float but they do
They can go through any depth of waterEckardt says Theyre fully amphibious
In the water the six-wheelers can carry twopeople the eight-wheelers can carry four peo-ple With their wheels as propellers the Argoscan go 25 mph on water
We dont actually drive the vehicleEckardt adds we propel the vehicle throughthe water
An Argo typically costs $6000-$11000Gear Companies With End-ProductsAccording to Hallila its unusual for gear
companies to makeend-products Asheexplains gear companies dont want to competewith their own customers
Hallila knows of no other gear company thatmakes water turbines At 000 Eckardt saysthere is one other manufacturer of amphibiousvehicles but it isnt a gear company Also Heinisnt aware of any other gear companies withwind machine operations
The Machines MarkieampsHallila describes the water turbine market as
a relatively small market According to Heinthe domestic market for wind machines is prob-ably either shrinking or staying the same but
20 MAYJUNE 2001 GEAR TECHNOLOGY WWWgSllflsclmoiogycom wwwpowerltllnsmissioncom
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
Tell Ua WIIeIYDII T1IiK
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If you would like more information abouta-tllo Bear CO circle1fUATA Geelllld circ _00 Drive a Gear Ltd clrcl aU-If you would like to respond to this or any other articlein this edition of GeBr Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-6618
A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
T Us YOII Think If you found this article of interest andor usefulplease circle aMIf you did not care for this article circle ~
If you would like more information about Pialllurgh ccirc ~If you would like to respond to this or any other articlein this edition of Gear Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-661 B
WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
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Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
I--+--+--t--~ T1RUE DIMENSION GEAR INmiddotSPEC
Provides actual overballpin measurmenof any helical orgear or splin WiLU t-
the need ofcostlysetting masters
Ga~ Division
d Tool _I
9 ODS ID
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851 OHIO PIKE middotCINCINNATI OHIO 45245 bull (513) 152-6000 bull FAX (513) 75205599
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Learn mare at ShON Central
bull Exhlibiitor Liistbull Booth Descriptions
bull NEW THIS YIEAIR Online Videos
Plan our visit to tile sllow months in advainceat Shaw Central
wwwgeartechnologeJlpocomwpowerrtatlamfsslotlcom WWWg9Iut9chnoloflycom GEAR TECHNOLOGYmiddot MAYIJUNIE 2001 45
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
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powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
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ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
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Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
the foreign market appears to be growingAs for amphibious vehicles Eckardt says the
markets size is difficult to determine Hede cribes it as wide but hallow explaining thereare many niche u e for ampbibious vehicles
But he adds the market has been growingrapidly during the past few years It mirrors-ina way-the ATV market for the four-wheelers
Niche in ProductionHaving gone a tep further the three gear
companies have made their end-products pari oftheir operation BUl Ole step hasnt had thesame effect on all of them
ATA Gears makes its small-scale water tur-bines only when customers specially order themAnd it designs them to suit ell iomers localconditions Amarillo Gears subsidiary makes itsend-product as part of its daily operationsAmarillo Wind makes 200-300 wind machineeach year Likewise anG makes its amphibiousvehicles in its daily operations-about 2000vehicles each year
Hallila says the water turbines are a special-ized part of ATA Gears not in the companysmain tream operations For example ATA Gearshas 170 employees but the number of employeesmaking water turbines varies depending onworkload
Hein also describes Amarillo Wind a a spe-cialized part of Amarillo Gear nol in its main-stream operations Amarillo Gear has more than130 employee Amarillo Wind has 21-andonly eight of them build wind machines
ButODG amphibious vehicles are its main-stream Out of I IO employees 30 work in alesand admini tration 34 in the gear divi ion and46 in the vehicle divi ion 0
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A waler lurbine rom AlA Gea~ includes IIset 0 its spiral blvel ijelf8 how in hI iIIltntld troISsettion Enlering theturbine water IIms themiddot rner blades (rigmiddotht) drivinglll ball md Ipinl bInilUfS hllt power the QelUlretof
ATA Gears middotturblnes generate power as part ofa dam as in tbis i1Luslrlltion To g lemla pOWlr middothmiddotturmiddotbines usually need waler with a head of IHOleel lowing IIIa ~al 0 3O-1i80(]cubic middotamp1 per nconll
wao erlrBnsmlssioncam QBarlechnologycom GEAR TECHNOLOGY MAYJUNE 2001 21
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
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WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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(4a)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
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Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
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We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
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cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
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---------------- --------
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and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
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COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
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HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
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AUSTEMPERINGIMIPROViES MATERIAL
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NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
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SERVICE
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
This paper was p~-
sented at hI 1999 Fall
Technical Muting of theAmerican Gear Manuat-
lurers AssociationPrinted with permis-
siO1of the copyright hold-er the American Gear
Manufacturus Association1500 Kill Street Suite201 Alttandria Virgin22314 Copies of the paper
are available from theAssociation
Statementlaquo presenfed
in this paper are those of
flu author and may no rep-resent the position or opin-ion ofhe Amertcaraquo GearManufacturers Associanafl
Figure J-Traditional in-spection cover
Figure 2-TlIleaded pipeplug inspectifJI porl
Gearbox FieldPerformance From a
Rebuilders PerspectiveCharles D Schultz
IntreducrionThe major focus of the American Gear
Manufacturers Association standards activity hasbeen the accurate determination of a gearboxs
ability to transmit a specified amount of powerfor a given amount of time The need for a levelplaying field in thai critical arena was one of the
reasons the association was formed in the firstplace Over the past 85 years AGMA committees
have spent countIes hours discussing the best
ways to calculate the rating of a gear set oftenarguing vigorously over factors that varied the
resulting answers by fractions of a percentagepoint WillIe all that science was being debatedin test labs and conference rooms an over the
country our industrys customers were conduct-ing their own experiments through the daily oper-ation of gear-driven equipment of all types
Unfortunately the results of those test pro-
grams are usually unavailable to the design engi-neer unless failure occurs during the relativelyshort warranty period offered on new equipmentMy employer the Pittsburgh Gear Co bas been
engaged in the repair rebuilding and field servic-
ing of gearboxes for many years The record ofthat activity provides some interesting insights
into what happens 10 gearboxes long after theirwarranties run 0111 (See Appendix A) While themajority of our customers are in the steel busi-
ness equipment from the chemical mining androck-quarrying industries has also been repaired
At one time or another products from mostdomestic and foreign suppliers have beenserv-iced The gearboxe cove much ofAGMAs his-tory and include most of the designs populartoday One of the drives Operated by a local cus-tomer was put on-line m 1921 and hasnt mis eda day of WOlK yet That type of performance isexceptional of course but it certainly inspiresrespect for the designers who labored in OUT tradelong before ihe advent of the computer
~t is 101 deference to those creative engineersthat] encourage todays gear designers to avail
themselves of any opportunity to study long-termperformance Having spent most of liIe last 2Syears engaged in gearbox design and develop-ment exposure to the far less glamorous ide ofthe business has been extremely beneficial to mydesign work In this paper Ill try to share some
of the things Ive learned and how theyve affect-
ed my design philosophyFailuR Definition
Our customers have their own definition of
gear failure and it has nothing to do with bend-ing tre or durability rating The average mil)
upenntendent care about ollly one thing Canthe equipment work today IT a little pitting or amall crack appears the user couldnt care less if
production can continue While some of the moresophisticated plants are rapidly moving towards apredictive maintenance environment the V3St
majority of mills react only [0 catastrophic break-downs Weve seen some incredible perform-
ances by gearboxes run completely without oilfor months or missl_ng sizable tooth fragments
due to bearing-related misabgnment We haveeen very few failures caused by overrating or
misapplication although overloads due toprocess line crashes and field modifications
remain a significant problem AGMAs standards
writers and the application engineers can be justi-fiably proud of their work
The arne pride cannot be shared by the plant
maintenance crews however The most commoncau es of failure recorded in OUl database are Iackof lubrication poor lubricant quality and debridamage Tooth breakage i rarely een unlessbearing damage extreme tooth wear or debris isinvolved Pined teeth are usually Iefl untreateduntil the drive becomes aoisyenough to attractattention or someone becomes alannedat themetal seen during an oil change While there arecertainly design deficiencies that contribute tothose problems mo t customers would enjoy
lower overall operating costs if they did a betterjob of monitoring the equipments oil quality For
22 MAYJUNE 2001 GEAR TECHNOLOGY wwwgsartschnorogycommiddot wwwpowsrtransmuoncom
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
T Us YOII Think If you found this article of interest andor usefulplease circle aMIf you did not care for this article circle ~
If you would like more information about Pialllurgh ccirc ~If you would like to respond to this or any other articlein this edition of Gear Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-661 B
WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
Solutions for yourgear manufacturingneeds~owefiedbySamputensil
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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CIRCLE~79
(4a)
(4b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
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_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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SPIRAL BEVEL GEARS~Transmissions~
Spiral amp Straight BevellGear ManufBctulngCommercial to aircraft quaiity gearing
Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
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June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
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May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
-
PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
ly reduced both their maintenance staffs and their
spares inventories Among the most distressingproblems we have to deal with on a regular basisis the housing bore damaged by II spun bearing(See Figure 6a) Repairing a damaged housing isvery time consuming and costlyespecially onspecialunits with multiple split lines ora dividedpower path The A[SE heavy-duty crane specifica-tion (see AISE Technical Repott 6 June 1996)requires that bearings be mounted in replaceable
cartridges (see Figure 6b) due to the difficulty inremoving the housings from their lofty perches for
re-machinlng Superintendents faced with expen-sive lin-place machining of gearbox housings
grouted into the floor quickly make sure futurepurcha e specifications follow the AISEs exam-
ple Except for bearings that must float axially bull itmight be worth studying the effects of tighter out-side diameter fits on most housings Where pas i-
ble anti-rotation pins (see Figures 7a and 7b)seem to be quite effective
Some ofthe lubricant loss experienced ill themin can be traced to worn eal diameters Manyoutput shafts are made of material that has notbeen heat treated Consequently those shaftshave soft seal diameters which wear out ratherquickly After-market wear sleeves have provento be quite effective in fixing tbat problemalthough the units have to be removed from theirmountings and stripped of their couplings to
the designer knowing that even the most state-of-
the-an gearbox will operate in an environment fullof soot sand water blunt instruments and
mechanics struggling to keep everything movingcan help reduce the anxiery of determming thecontact stress to the thjrd decimal place
Design Praetlee CbangesObserving the maintenance problems first-
hand has resulted ill sornechanges to my designphilosophy For example unless a customer
insists we no longer use the traditional bolt-oninspection covers (See Figure I) Weve found thethin plates almost impossible to seal against mois-
ture and have noticed that many time the debris
that inflicted the final damage to the gears was asmall cap screw used to attach the plate Our tech-nicians have found all incredible amount of stuff
inside gearboxes with large covers includingwrenches screwdrivers files and flashlights
Weve arlen joked that tile bigger the inspectioncover the bigger the debris While handy for gearinspection the covers ought to have a wantinglabel affixed reading No user serviceable parts
in here Weve switched to large threaded pipeplugs for inspection ports (See Figure 2) Theyseal tightly against water permit quick inspection
oftooth condition and are impossible to drop intothe Oil sump The pipe wrenches required toremove them are 100 big to drop though the hole
although the tiny flashlights favored by somemechanics do present a continuing hazard
Weve al a become believers in low oil
level sensors (See Figure 3) Originally wary ofputting delicate electrical device in the rough-
and-tumble mill environment observing a plantstart-up where the only gearboxes run dry werethe only ones without the sensors was convincing
evidence of their value Weve also been increas-ing the robustness of the external lubricationplumbing used on both new designs and rebuildsLube lines apparently make excellent ladders forclimbing serve as emergency crane hooks and areeasily snagged by passing loads One of our cus-tomers now has us fitung his more susceptiblegearboxe with guards made of O25-in plate toprotect them from dWIIage (See Figure 4) FOrmost pressure lines weVe switched to high-qual-ity bydraulic hose after discovering that even thebravest mechanic wont use them for a step or alift point (See Figure 5) So far the customershave been very accepting of that change especial-
Iy when they realize it is much cheaper to make anew hose than it is to repair a damaged pipe
Fast turnaround on repairs is increasinglyimportant to the mills many of which have great- FigulIe 5-ExIemQII14brbQliOlli system with hydnJUlic hose
Figure 4-Guardtd lllbrlcation system
Charles D Schultzis vice president of engi-neering al Pirulmrgh GearCo A registered profession-al engineer in flennryivaniaand Wisconsin he hasworked ill the geGr industryfor 30 years
w powetlransmlulonrom wwwgmiddotsIJrtechn0ollycom GEAR TECHNOLOGY bull MAYJUNE 2001 23
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
T Us YOII Think If you found this article of interest andor usefulplease circle aMIf you did not care for this article circle ~
If you would like more information about Pialllurgh ccirc ~If you would like to respond to this or any other articlein this edition of Gear Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-661 B
WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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The Crown Power Train with its remarkable experience in gearsproduction has developed a CNC gear inspection machine tor
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_-----------_1 GEAROESIGNFOCUS _
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arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
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110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
I--+--+--t--~ T1RUE DIMENSION GEAR INmiddotSPEC
Provides actual overballpin measurmenof any helical orgear or splin WiLU t-
the need ofcostlysetting masters
Ga~ Division
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9 ODS ID
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bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
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STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
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o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
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Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
a) Conventionaltjmounted bearing
Housing bore urface prone10 damage if bearing spi ns
Housingbore surfaceunaffected bybearing spinInexpensivecarrier can bereplaced
b) Carrier orcartridgemounted bearing
Figure 6-Bturing mouJltingol exteruJed ervklaquo life
- Slot ground intobearing cup
a) Single-row taperroller installation
b) Double-row taperrolleror sphericalrollerinstallation
1- --- --
Figure 7-Commo ann-rouutoraquo pin designs
a) Conventionaldirect sealmounting
Bhn minimum
b) Severe-duty sealdesigngreasepurgedwith Ireplaceablesleeve andprovisionsfor splitouter seal
Figure S-Stlal de~igns01 er~fIdedserviclaquo lift
Figule 9-Example of miscellaneous damage
in tall them Coupling removal occasionaJlycauses enough additional damage to the shafts tonecessitate their replacement anyway We rec-ommend that seal diameters be at least 285 Bhnon all shafts unless wear leeves are lined (SeeFigures 8aand 8b) Chrome plaling or inductionhardening ispreferred by orne customersalthough those processes add to the turnaroundtime For severe-duty wash down environ-ments special seals such as packing glands arewell worth the extra expense
We are still trying to develop better ways tokeep water out of the sump Continuous castergearboxes are particularly prone to water contam-ination even when fitted with expansion cham-bers rather than breather A a result of that prob-lem the mills have reluctantly gone to trier pre-ventive malntenance programs all those criticaldrives Through careful attention to details suchas chrome plating seal diameters and regularlyrepainting the interior surfaces of the housing wehave been able to lengthen the time betweenrebuild by 50 The most amazing thing to meis how well the carburized bevel gears have heldupafter being lubricated with watered-down oilWn similar situationstmough-hardened helicalgears destroy themselves in a maner of weeks
Wear is a much more common gear failuremode than tooth breakage 011 the drives that werepair As noted earlier customers seldom react tothe appearance of pining even on carbunzedgears Severe wear frequently produces a notice-able change in how the gearbox sounds and drawsthe interest of the mechanics Carburized gearstypically outlast several sets of bearings unlessthe bearings are allowed to deteriorate so far thatmisalignment results in evere pining or toothbreakage In similar applications through-hard-ened gears do not seem to hold up as well and aremore frequently replaced at the same time as thebearings The Jongevityof through-hardened gearset i adversely affected by the high face-to-diameter ratios used ill some designs whichmake the sets prone to deflection-related loaddistribution problems In redesigning those gearsets we often use the additional capacity affordedby changing to carbusized gearing to reduce theface width thereby reducing jhe facediameterratio to more conservative levels
Basic design problem are relatively rare bUI
when poundheyoccur the customer has to live with theresults for years One installation we service has a49 1ratio doable-reduction gearbox Lfla very tightlocation The 7 I gear sets have face-to-diametermtios of over 20 and require replacement every J8
24 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgBsrI6chn0ogycom bull wwwpowBrlransmlssoncom
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
T Us YOII Think If you found this article of interest andor usefulplease circle aMIf you did not care for this article circle ~
If you would like more information about Pialllurgh ccirc ~If you would like to respond to this or any other articlein this edition of Gear Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-661 B
WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
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H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
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May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
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AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
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May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
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THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
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(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
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D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
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_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
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Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
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We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
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New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
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Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
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New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
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AUSTEMPERINGIMIPROViES MATERIAL
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NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
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shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
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Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
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SERVICE
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
to 24 months Wellave other frequent visitors
with multiple input-multiple output configurations
that suffer from recirculating powerploblemsImproved part quality or increased hardness has
lengthened the time between rebuilds but the lackof redesign options prevents effective long-termre elution When designing our own specials we
try to give ourselves room for future upgrades bytaking a conservative approach to ratio selectionface-to-diameter proportions and internal housingclearance
DesigJI for Extended LifeWhile recognizing the commercial limitations
impo ed upon us by the global marketplace lbelieve that we can design for extended life byconsidering the problems likely to be encountered
during the 15- to 25-year operating life of the typi-
cal process line and addres sing them al the original
equipment level Not every gearbox needs car-tridge bearings but all deserve a water-free Slimp
Following the AISEs example of graduated serviceclasse to account for duty cycle reliability expec-
tations and life requirement would go a long waytowards improving customer satisfaction with ourindustry With~n the context of tho e service class-es it would be po sible to addre s detail de ignissue in a way that provide a consistent levelplaying field for all competitors without forcingcustomers to develop their own in-house specifica-
tions I realize the difficulty of changing from a cat-alog selection system based upon a list of applica-
tions and service factors to a system that includesnon-gear related factors uch as housing design Itwas just a few years ago however that we consid-
ered 10000000 cycles 10 be infinite life despiteknowi ng that that was less than I IX)hours of use for
the typical high-speed pinion A proposal for serviceclasse is shown ill A-ppendix B
AcknowledgmentsThe author would like to acknowledge the
assistance of Will Willman and Ed Besong ofPittsburgh Gear Co in preparing some of the pho-
tographs and illu tration used in this paper 0
T Us YOII Think If you found this article of interest andor usefulplease circle aMIf you did not care for this article circle ~
If you would like more information about Pialllurgh ccirc ~If you would like to respond to this or any other articlein this edition of Gear Technology please fax yourresponse to the attention of Randy Stott managingeditor at 847-437-661 B
WWWpOwmiddot rtrsnemtestoncom WWWgflsrtBchllologycom GEAR TECHNOLOGY MAYJUNE 2001 251
AppendilAdause or repair summaryDescriUODI of IOrdersContaminatedloil 353
ID Toml1611205964905174
Cause of RepairInadequate lubricantlow Oil LevelBearingsMiscellaneousOverloadPreventive MaintenancePrecautionary Repairs
Totai
Insufficient oilWorn orfailed bearingsNon-Gear Searing lubeGear or bearing damage
44921111198381
5962188
272
IComments1 Bearings and seals were changed on all gearboxes unless the customerspeciflcallyrequested their re-use2 Worn or pitted gears were not changed unless authorized by the customer3 The Overload cBtegory includes all tooth breakage and indications of plastic flowFrequently the problem occurs when the process line crashes putting untcrasaanloads on the gears bearings and shafts -4 The ~Inadequate Lube category includes units with evidence of contamjnation andgeneral bearinggear wear The low Oil Level category was reserved lor cases of rol-atively sudden failure due to temporary lack at oil rather than long-term damage5 The Miscellaneous category includes physical damage to the gearbDx by externalsources leaks not related to seals handmiddotof-assemblv changes COlUplingchanges andmodification requests (See Figure 916 The Preventive Maintenance repairs are made based upon previous expenience thatfailure to do so on II regular basis will result in unplanned shutdowns
Class 2 3 4
Description IRegular Duty Heavy IDuty Severe IDuty Critical Duty
Abbreviation I AD liD SOl CD
Minimum Gear
Strength SF 125 175 250 300
Lube System Splash Splash Pressure Pressurewith filter with fiHer
Min Gear IDesign Life 110000hrs 150001hrs 20000 hrs 30000 hrs
Min Bearing L-l0 Life 10000 hrs 20000 hrs 40000 hrs 60000 hrs
Bearing Mounting Conventional Conventional Cartridge Cartridge
Seal Type Single Lip Single Lip Grease Plrged Grease Plrlledwith provlsons With prOVISIons
lor split fOr splilraplacemants replacements
Shaft Surface 220 Bhn min 285 Bhn min Replacea~le Replaceablesleeve reqUired sleeve requ ired
-----
Gea~boxesrepairedincluded
Alten Engineering Oivision Westerman CompaniesAmarillo Gear CDBr~wning a division 01 Emerson Power TransmissionCIucago GearmiddotDO James CorpCleveland Gear CoCone Drive a division of Textron Powar TransmissionDavid Brown a division ofTextron Power TransmissionDelroyd Worm Gear Products a division of Nuttall Gear LLrIDodgea division 01 Rockwell AutomationIDorns CoFalk CorpFessler Machine CoFiend er GorpFoote-JonesIllinois Gear a division of Regal-Beloit CorpHansen Corp a Minebea Group companyHarnischfeger Industries IncHitachi Zosen CorpHorsburgh amp Scott Co _ILohmann + Stolterfohl GmbHMorse a division of Emerson Power TransmissionNord GearNuttall Gear LLC bullPhila delphia GearPrager IncRenold picSantasalo Gears [now Metso Drives)SEW EurodriveSumitomo Machinery Corporation of Americ81Xteklnc
Solutions for yourgear manufacturingneeds~owefiedbySamputensil
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
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CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
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AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
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May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
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THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
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D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
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_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
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Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
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New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
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and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
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New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
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LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
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11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
We narrowed the focus
To give you a broader view
GearTechnology Center
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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Midwest Transmissions amp IReducersISO compliant
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
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Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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The Crown Power Train with its remarkable experience in gearsproduction has developed a CNC gear inspection machine tor
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Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
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Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
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Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
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i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
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STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
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STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
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- Competitive Prices-Relap amp Replating Service
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New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
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and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
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IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
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A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
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AUSTEMPERINGIMIPROViES MATERIAL
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LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
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RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
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shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
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Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
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Direct your inquiries toRon lfIumphrerGeneral Manage
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SERVICE
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
Design Forrnulasfor Evalullting Contac1 Stress in Generalized Gear Pairs Page 31Q amp A Dynamic Loa~sWorm GeBrsamp Geometry Factors Page 39Load Distribution in PIanetary IGears w Page 41
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Weve consollldated ell of our NolthAmerican gear cutting technologies into oneiindependent organization And moved theentlrecperatlcn to a new technology centerlin the IDetroit area at the hub of globalpowertreln engineering
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If your current manufacturingchallenges require the detelted focus of theworlds foremost authority on ~gearproduc-tion give us a call After aU were In theneighborhood
bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
wwwpowIJrtrIJflsmissioncom wwwgearlmiddotschflologycom GEAR TECHNOLOGYmiddot MAYtJUNE 20Ql 43
20IREISHAUERCNC MACHINIESARE REAIDVTOWORKFOR YOU
The Crown Power Train with its remarkable experience in gearsproduction has developed a CNC gear inspection machine tor
bull quick easy and affordable servicebull Check cylindrical gears in lead pitch and Involute prefilebull Module between OSmm and 1600mm (1610 SOOP)bull Outside diameter between1000mm and 42000mm (4 to 165)PRICE $ 120OOOOO-FOBCrown included three days of talnlng
Request InformationCall +39 030 7156530Fax +99 030 7059035httpwwwcrownltcrow-ncrownlt
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Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
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Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
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Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
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bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
I--+--+--t--~ T1RUE DIMENSION GEAR INmiddotSPEC
Provides actual overballpin measurmenof any helical orgear or splin WiLU t-
the need ofcostlysetting masters
Ga~ Division
d Tool _I
9 ODS ID
I
851 OHIO PIKE middotCINCINNATI OHIO 45245 bull (513) 152-6000 bull FAX (513) 75205599
CIRCLIE 13jt
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bull Exhlibiitor Liistbull Booth Descriptions
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Plan our visit to tile sllow months in advainceat Shaw Central
wwwgeartechnologeJlpocomwpowerrtatlamfsslotlcom WWWg9Iut9chnoloflycom GEAR TECHNOLOGYmiddot MAYIJUNIE 2001 45
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
I till Us DIIIk
I
IIj
I
_ CIRCLE 1fl i - ~_-o_-_
46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
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STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
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powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
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RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
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Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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(4a)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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SPIRAL BEVEL GEARS~Transmissions~
Spiral amp Straight BevellGear ManufBctulngCommercial to aircraft quaiity gearing
Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
I--+--+--t--~ T1RUE DIMENSION GEAR INmiddotSPEC
Provides actual overballpin measurmenof any helical orgear or splin WiLU t-
the need ofcostlysetting masters
Ga~ Division
d Tool _I
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851 OHIO PIKE middotCINCINNATI OHIO 45245 bull (513) 152-6000 bull FAX (513) 75205599
CIRCLIE 13jt
Learn mare at ShON Central
bull Exhlibiitor Liistbull Booth Descriptions
bull NEW THIS YIEAIR Online Videos
Plan our visit to tile sllow months in advainceat Shaw Central
wwwgeartechnologeJlpocomwpowerrtatlamfsslotlcom WWWg9Iut9chnoloflycom GEAR TECHNOLOGYmiddot MAYIJUNIE 2001 45
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
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Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
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PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
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bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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(4a)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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SPIRAL BEVEL GEARS~Transmissions~
Spiral amp Straight BevellGear ManufBctulngCommercial to aircraft quaiity gearing
Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
MIIlWist GEARamp TOIl IINC
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
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bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
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Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
-
PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
bull G~R DES~GNFOCUS ----_
Design Formulas forEvaluating Contact Stress in
Genelralilzedl Gelarl PairsIntroduction
A very important parameter when designing a gear pair isthe maximum surface contact stre s that exists between two gearteeth in mesh as it affects surface fatigue (namely pitting andwear) along with gear mesh losses A lot of attention has beentargeted to the determination of the maximum contact stressbetween gear teeth ill mesh resulting in many different for-mulas Moreover each of those formulas is applicable to a par-ticular class of gears (eg hypoid worm spiroid spiral bevelOf cylindrical-spur and helical) Morerecently FEM (the finiteelement method) has been introduced to evaluate the contactstre between gear teeth Pre ented below i a ingJe method-ology for evaluating the maximum contact stress that exists Fig1-Two pitch circles lncont8ctbetween gear teeth in mesh The approach is independent of llIe r----------------------- =r=t
gear [Oath geometry (involute or cycloid) and valid for any geartype (ie hypoid worm spiroid bevel and cylindrical)
Relative CurvatureThe contact stress between two gear teeth in mesh depends
on the relative gear tooth curvature material properties of thegear teeth and the transmitted load between the gear teethDetermination of the relative gear tooth curvature can be prob-lernanc for certain gear types The relative gear tooth curvaturebetween two gear teeth in mesh results in a contact that is eitherpoint-eentact or line-contact lit general the tran verse contactratio for two gears in mesh is greater than zero and line-contactexists between the two gear teeth in mesh Helical or spiral gearswith line-contact experience both axial andtransverse displace-ment during me h Such condirionsare inherent for any toothprofile type (namely involute or cycloid) Point-contact is the Fig 2-G88r nomenclature
David B Dooner
alternative cenario for two conjugate surface in me h Thatcondition occurs when the transverse contact ratioi zero Thattype of contact applies to circular-are type profiles (IlamelyNovikov-Wildhaber or BBC)
Determination of the relative gear Iooth curvature AI(between two planar involute gear teeth is demon trated prior topre enting he relative gear toolh curvature between two gener-alized gear teeth Depicted in Figure I are two involute gearteeth iII me h The radius of the input pitch circle is RibullwhereasR i the radius of the output pitch circle Pi and Po are the radiiof curvature for the input and outpur gear teeth respectivelyProjectimg the pitch radii R and R onto the contact normal
pitch surfaceof oulpu1llear
pitch circleL-----~~Uc----- langenl
bull Itooth
~ ccntaet nermalI
pilch surface of irrpulgear
gcnunlQr omiddotrhyperboloidalpitch surface
Iallis of rotation(output gear)
axis of roIalion (inpul gear)
David BDooneris an associate professor in thedepartmm ofmechanical engi-neering aI the Uni versify of PuertoRicomiddotMayagaez Ilis researchinvolves a universal approach forthe concurrent design and manumiddotfacture of gears That generalizedapproach can be used 10 producegears with any number of teethany face width and any spiralangle The approach applie 10helical bevel wonn spiroidhypoid ami nOli-circular gears
wwwpowfutransmissioncom bull WWw1l8middotartechnolollycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 31
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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CIRCLEli1(6a)
_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
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For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
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Fr ---i 0 C[ III I I
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Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
If you found this article of interest andoruseful pI sa circle
MAYJUNE 2001 bull GiEAR TECHNQlQGY wWlIgurechlloloQycom bull wwwpowerlrslIsmluloncom
GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
wwwpowIJrtrIJflsmissioncom wwwgearlmiddotschflologycom GEAR TECHNOLOGYmiddot MAYtJUNE 20Ql 43
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
CIRCLE
IIEHOlDPreclsiol1 Technologies
1 GEAR DESIGN FOCUS _
yields
Pi = Rsincentl (Ia)
Ob)
where cp is theangle between the pitch circle tangency and thetooth contact normal For planar curves tile curvature 1lt andradiu of curvature p are reciprocals (ie bull K lp) Thu bull rela-tive gear tooth curvature ~K can be expressed as follows
w ])~K= +-- Po bull(2a)
or
81( 1( -R + ) Ini 0 SLn
(21))
whereR radiu of input pitch circleRo radius of output pitch circlecentI pre sure angle
The above expre ion establishes a unique relation betweenthe pres ure angle centI the pitch radii R and R and the relativegear tooth curvature ~K Regardless of the radii of tooth curva-ture Pi and Po the relative gear tooth curvarure ax depends sole-ly onpitch radii R and Ro and pressure angle 41 The above rela-tion for relative gear tooth curvature ~sfor cylindrical gears withspur-type gear teeth Furthermore the relation is valid only forcontact at Ute pitch point
Prior to pre enting a generalized relation for the relative geartooth curvature it is necessary to establish some ncmenclanrre andintroduce certain expre ions Depicted in Figure 2 are two pitchsurfaces in mesh two axe of rotation ljElJldl~the perpendiculardistance E between the two axes Ii and 10and the included angle Lbetween the two axes Ii and 10 The piteh urfacesin Figure 2 arehyperboloids Notice in Figure 2 that each byperboloiclal pitch sur-face i determined by a series of straight lines Hyperboloids canbe envisioned the wface produced by rotating a line or gener-ator about a central axis For example rotaringjhe common gen-erator lilo between the illpul and OUtpllt body about the axis of rota-tion Ii produces the input hyperboloidal pitch surface The shape ofthe hyperboloidal pitch surface depends on an angle II and dis-tance u The angle 11 is the cone angle of the generator and u is theradiu of the hyperboloidal pitch urfaceat iliethroat Introducingup as he radius of the inpm hyperboloidal pitch surface and Upo asthe radius of the output hyperboloidal pitch surface then up+ Upo
= E for two hyperboloidal surfaces in mesh Similarly defining ~as the can angle foribe input hyperboloidal pitch surface and llpoas the cone ~e for the output hyperboloidal pitch surface thenOlp + ~ = L for two hyperboloidal pitch surfaces in mesh Alsoshown in Figure 2 is the distance wp between the throat and pointp As the twohyperboloids rotate they are always in contact alongthe common generator
Cylindrical gearing OCCllJS when die angle I between theinput axls of rotation and the output axis of rotation is zero (ie
32 MAYJUNE 2001 bull GEAR TECHNOLOGYmiddot wg6llmiddotrI6chnl1lrom bull ww po efIIsmssJoIIcom
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
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H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
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May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
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AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
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May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
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THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
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(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
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D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
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_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
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Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
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We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
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New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
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Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
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New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
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CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
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CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
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NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
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HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
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RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
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GIEAR TOOTH IGRINDINGSpur bull IHelical
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Direct your inquiries toRon lfIumphrerGeneral Manage
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1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
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GEAR TOOTHGRINDING SERV~CES
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HOB SHARPENINGSERVICE
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bull THIN RLM COATINGSWest Branch Industries
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SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
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Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
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bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
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Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
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MAAG PARTS AND SERVICE
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GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
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Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
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Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
_---- GEAR DESIGNI FDCUlS1 _l= o and hence me con angles crmd laquopo are al 0 zero) fugen-eral II gear type depends on hom the center distance E (offset) andangle 1 between the input and output axes of rotation When thedi tanee E between two axes of rotation is zero then the pitch sur-faces become cone and the throat radii uP and upltgtare zeroAlternately when neither E nor l is zero then the two pitch sur-faces are hyperboloids Equation 2b for relative curvature til( wasderived in terms of cylindrical pitch surface and consequently itil101 valid for conical or hyperboloidal pitch surface
All importam parameter for pecifying relative gear toothcurvature is the effective radius The effective radius is the dis-ranee between the point p on the pilCh surface and the axis ofrotation as shown in Figure 2 For generalized gear pair with acon tant inputoutput gear ratio g the effective radii Uel and Ueocan be expre ed
whereupi radius of the input pitch urface (atthe throat)uJXl radiu of the Olltput pitch urfaee (at the throat)E shaft center di tance between he two axes of rotation
(up + Upo= E)wpi axial position of tangent point on input pitch surfaceWpo axial position of tangent point on output pitch surface
(wp = -wpo)
Ilpi cone angle of input pitch surfaceClpo cone angle of oUlput pach surfaceL the included hafl angle between the I[WO axes of rota-
tion (01 + 00 = L)11is also convenient [a introduce the following relations
where
uposi notanYPo = ~~=~o====
uJXl2cOS2-a+ Wpo2sin2Clpo
to determine relative gear Loath curvature It is of ceatral impor-tance to know th at the gear ratio g is equal to the ratio of radiil Rand R (ie g = RlRo) C-one angles ~i and laquopo are zero fOJ
cylindrical gears and con equently Ypjand Ypo are also zero Forbevel gears the pitch radii up and upoare zero such that Ypi and
1110 reduce to zero For spur gears jI is zero In general the extreme relative curvature between two gear
teeth in mesh can be determined with the following expressions
(3a)
(3b)
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CIRCLEli1(6a)
_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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SPIRAL BEVEL GEARS~Transmissions~
Spiral amp Straight BevellGear ManufBctulngCommercial to aircraft quaiity gearing
Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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Provides actual overballpin measurmenof any helical orgear or splin WiLU t-
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wwwgeartechnologeJlpocomwpowerrtatlamfsslotlcom WWWg9Iut9chnoloflycom GEAR TECHNOLOGYmiddot MAYIJUNIE 2001 45
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
_____________ GEAR DESIGNIFOCUS _
tooth profile with lip relief
Fig 3-Tootb profilemodification
ellipticalccntact
rMajor semi-axis of contact ellipse
Iiig 4-StniSI intensityfo ellipticill comet
HVpoid
Spiral bevel Splroid
Figi-Gear pairs
whered~ minimum relative curvature between gear teethdKmu maximum relative curvature between gear teethRi virtual radius of the input hyperboloidal pnch surfaceRo virtual radius of the output hyperboloidal pitch surfacelp instaruaneous piral angle of the input gear (pi == Ipo)centgtn normal pressure angle1 included sha uft angle
The above formulas for extreme relative gear tooth curva-ture are applicable forhypoid spiroid worm bevel and cylin-drical gear pairs Furthermore those formulas are independentohhe type of gear loath profile Recognize that when E = 0 (ie bullplanar gearing) and = 0 (ie spur gears) Equation 2band theabove relation for maximum relative gear tooth curvaturetlmax are identical The mathematical development of iheabove expression involves many mathematical relations andonly LIteresults are presented Additional insight into LItemath-ematical derivations is provided in Reference I_
Profile ModificationIdeally two gear teeth in mesh are in line-contact for gear
pairs with involute-type tooth profiles However gear designersintroduce both proftie relief and lead crown to accommodateerrors in tooth spacing runout misalignment and deflectionsGear teeth with profile or tip relief have a reduction in tooththickness in a particular transverse plane The magnitude of thetip relief is usually restricted to micrometers (IJlm)or a lew thou-sandths of an inch Crowned teeth have a reduction in tooth
thickness in the lengthwi e direction of the gear tooth The mag-nirade of crowning is restricted to a few micrometersacm s thetooth face Depicted in Figure 3 is a tooth profile with tipreliefand lead crown Such profile modification reduces theoreticalline-contact tc point-contact Consequently the above relationsfor extreme relative gear tooth curvature (ietlKmbullbulland tlrnm)must be modified to account for crown and profile relief
There is no established standard for specifying tooth profilemodificarion Here the deviation in ideal tooth profile is quadrat-icTip relief and leadcrown are specified here in a manner anal-ogous to the specification of addendum and dedendurn That isachieved by introducing a tip relief constant o and a lead crownconstant Bw Given the following tip relief con tant 011and leadcrown constant Gill the changes in CUIV8111reSxvandS~are
01]1=8 s
F2 + Fo2 p-o~ ( 2Pd r 15
a+b I ---p-
(7a)
(7b)
where~ lead crown constant0 tip relief constant
addendum constantdedendum constant
34 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgssrtechnoJogycom wwwpow)rtratlsmiss(oflcom
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
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Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
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they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
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We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
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OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
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CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
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HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
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Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
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IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
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Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
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bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
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800-447middot2392Fa 71H74-t003
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PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
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IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
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Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
_-----------GEAIR DESIGNFOCUS _r r face width IPd normal diametrallitch
lland ll are the same for both the input and Olltput gear Ielements suchthat the modified curvature become
I(8a) i NC
i ~g 300Il00 ~i ID
(8b) ~ ~ 200000ILl I ~
llIcmm change in minimum relative tooth curvamrei
OlCmu change in maximum relative toolil curvature jOK change in relative tooth curvature iII profile direction IEnc1IJ change in relative teeth curvature in lengthwise direction I
centIn normal pressure angle 1- __ --------------------I Fillmiddot amp-Mllximum contact ltrIu ICIIII 1lIfIll taco at C~Lllldnc I b-ypold b VIItVpl spiral angle I Ind _prald 111111Ipalr
F-or spur gears (ie bull tV 0) the face width Fi and Fo areidentical and equal to the distance between the heel and toe The Iabove change in relativegear looth curvature for modified gear I The tran mitted loadlletween two gear teeth is non-uni-Leeth mu t be added to the theoretical value Thu bull extreme gear formJy di tributed over the surtaee area of contact Depicted intooth curvature can be expre ed Figure 4 is an elliptical contact area with semi-axe r and rb
Kmin = bKmio (93) along with a parabolic Ire s intea ilY The sum of the pres ure I distribution over the area of contact results in th net force(9b) applied 10 the gear mesh interface Determination of the maxi-
II
OKp + ElK bull (sin2cent1n tan~pi)
~+ sin2lllo tan2ilj)Pi
500000
100000
400000
6K + ElKIl (sin2cj1o tanr1vp)I+ in2cent1n tan~pl
SpirDidBevelCy1indrinlHYpoid I
where
II IlOti
35 411 45 Ih 1
hia I position of contact in]
Contact Stress
_en technology10 sUlccess
IFasslerCorporation1311W layton AvenueMilwaukee WI 53207Phone (414)769~OO72Fax (414) 769--8610-mail fa5slerCexecpccom wwwfaesisler-agch
CIRCLE 125
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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SPIRAL BEVEL GEARS~Transmissions~
Spiral amp Straight BevellGear ManufBctulngCommercial to aircraft quaiity gearing
Spur helical splinedshafts internal amp externelshaved amp ground gears Spiral bevelllIlinding
Midwest Transmissions amp IReducersISO compliant
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
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June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
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AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
-
PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
_------------GEAR DESIIGN FOCUS _
That formula neglects common loading factors that instanta-neously increase the transmitted load POne such loading factor
that results in an instantaneous increase in transmitted load is
the dynamic load that results from transmission error A secondloading factor that increases the transmitted load is a distribu-
tion factor Shaft misalignment can result in a concentrated loadfor gears withl1igh contact ratios A third type of loading factorthat gives an instantaneous increase in transmitted load is anapplication factor Such factors are inherent in rough operat-ing machinery like internal combustion engines and crushing
(Lla) mechanisms Additional insight into those factors is provided by
AGMA Contact stress is further affected by tractive or shearforces that result from the relative sliding and friction at the
mesh and residual stresses in the tooth sub-surface The magni-(l 1b) tude of the shear load on the gear surface depends on the type of
lubricant and its thickness Simultaneously the gear designershould be aware that relative gear tooth sliding at the contact
mum contact stress is based 011 the following assumptions
gear tooth materials are elasticgear tooth materials are isotropicgear tooth materiall properties are homogeneouscontact area is frictionless andradii of curvature are very big compared with the semi-axes
contact ellipseThe maximum compressive stress is evaluated using a mat-
tress-based formula (see Reef 2) Hence it is advisable that the
elastic moduli of the foundations are similar in magnitude Itisrecommended that Hertzs formulas for predicting maximum
contact stress are used for gear elements with highlydissimilarelastic foundations Introducingthe constant
wbereP normal contact forceBi modulus of elasticity for input gearEo modulus of elasticity for output gearI Poissons ratio for input gear
110 Poissons ratio for output gearthe semi-axes of the contact ellipse become
ra= [c (~ t4 KJ W
_ [ ( Kmllgt ~14 ~1]13rb- C --- --Kmin Kmin
Table l-Gear Pair ParametersICylindrical Hy oid Bevel S iroid Cylindrical Hypoid Bevel Spiroid
2m 2m MQ 2JIQ E Eg (lbJin2Nm2) lID 3DIDD ~ BShaft center distance E [inJmm) 508 508 000 508 l1J1X10 207X10
M 9Il lK 00 JIi e Jlo (dimensionless) 0267 0287 0287 0287Included shaft angle 1 (degJrad) DD 1571 1571 1571 R(inJmml Q6m W Jill lllJl
315 l25 315 315 1695 3525 2914 300
Axial position oftoe WIO linJmm) 8255 8255 8255 8255 R (inJmm) L23i am 2ill ws3147 9634 lSM 6142
ill ill ill m 1 [degJrad) g L jIL IlAxjalposition of heel 111 (inJmmJ 12065 12065 12065 12065 0 1511 1511 1571
P[inJmmj 1049 54lI5 5Jll 8mNumber of teeth on input gear N integer) 14 15 12 2 Q Isectll ill
up Idegrad) 0 0461 0369 02341 Wli 0 ru
Number of teeth on output gear N (integer) 26 41 31 41 up) (degJrad) 0 llQ1 12111 13311 ~ I 15l1M1 ~ 3ill aLZl 1 (degJrad1 0 0099 0 1)021
Nominal spiral anglelj1p (degJradJ 03Il4 0620 0648 1411 II illli ~ ~3000 5U 65Jll illlI Yo(degJrad) 0 0373 0 0439
Nominal pressure angle (norman 41 (degrad) 0524 0976 1136 0834 lK 11in1mlIlm IllIW LlIZ5 IIIW0249 Osas US un
~ 00l OOQ 12Q()Km l1inJ1mJ IlJ3i1I 11M Mlffi MVli
I Input shaft torque T [ ) 1017 1017 WIJ 1436 S2S1 2118 11178 1)189
KmOinJlmJ Ilm DD22fI lll25II IIJJI1ll
Axial contact ratio mldimensionless) 15 15 15 4 om 01186 0984 4111
tom flinlmJ illli IlJill W il311U1 3412 3969 2525
Addendum constant (dimensionless) PjlbJN) lllZ illI Wli illBI03 ~51 8247 6~
Dedendum constant (dimensionless) C (in2mm2) UZ1l1~ UlWa 1mJ ~
0076 0Jl56 001III 0074
rlinmml lli1lI gm[ Q2lli JJmlip relief constant aldimensionlessl 001 001 0D1 001 11601 5419 6142 HilS
r~linmm) I2QIll ~ WIll ~0439 0866 0965 0412
Lead crown constant Iil (dimensionless) 002 002 002 002 (lI (ksVMPa) 1B ill ill m1018 823 100 2SZ5
36 MAYJUNE 2001 GEAR TECHNOLOGYmiddot wwwgesrtechn0oQycom bull wwwpowerfransmissoncom
wheremajor semi -axis of contact ellipseminor semi-axis of contactellipseconstantmaximum relative curvature with profile modification
Kmm minimum relative curvature with profile modification
The maximum contact stress Dc is obtained by integratingthe pressure distribution over the area of contact A aadequat-iag to the transmitted load P The maximum stress Oc is 3rrJ4times the average stress for an elliptical contact area and a pro-
portional stress intensity hence
3n P0=--- -----~----c 4 nrrb
(12)
Table L-Contact Stress Calculations
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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SPIRAL BEVEL GEARS~Transmissions~
Spiral amp Straight BevellGear ManufBctulngCommercial to aircraft quaiity gearing
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------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
Fr ---i 0 C[ III I I
----+------+--- ----
bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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The Crown Power Train with its remarkable experience in gearsproduction has developed a CNC gear inspection machine tor
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_-----------_1 GEAROESIGNFOCUS _
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arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
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12
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110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
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STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
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STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
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STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
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We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
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New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
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and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
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IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
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A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
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CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
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LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
_----GEAR DESIGNFOCUSI _zone can cause a rise in temperature at the mesh resulting in a
temperature gradient in the gear tooth and thus further affecting
localized tooth contact stressExamples
Four examples are presented to illustrate the determination
of contact stress between gear teeth in mesh The first exampleis a helical cylindrical gear pair the second example is a hypoidgear pair with non-zero spiral angle the third example is a spi-ral bevel gear pair and the last example is a spiroid gear pair(ie a hypoid gear pair with high spiral angle) Each gear pair
has a L5-inch face width The nominal gear parameters for eachgear pair are provided in Table I Graphical illustrations of the
gear pairs are provided in Figure 5 Intermediate calculations
and final contact stress are presented in Table 2 for the face mid-point Values for maximum contact stress are based on a singleconcentrated load and neglect load sharing resulting from highcontact ratio tooth deflections or wheel body deflections A
computer program has been written and the variation in contactstress across the face of the gear pairs is depicted irnFigure 6
SummarySimplified design formulas for evaIuatinglbe maximum contact
middot tress between two gears in me h are presented The melbodologyIs summarized as followsbull demonstrated that relative tooth curvature for planar gearsdepends on pitch radii and pressure angle
presented a generalized formula for extreme relative curvaturebetween gear teeth in mesh that is valid for any tooth type (involuteor cycloid and any gear type (cylindrical bevel hypoid spiroid orworm)bull presented a generalized formula for relative gear tooth curvaturefor arbitral) tooth profile modification (tip relief and lead crown)
presented explicir expressions for semi-axes of e1liplical contactbased on mattress formulabull presented formula for maximum contact stress between gearteeth andbull presented four example to illustrate the use of formulas to deter-mine maximum contact stress
ReferencesI Dooner DB and A A Seireg The Kinematic Geometry ofGearing A Concurrent Engineering Approach John Wiley and SonsInc New York 19952 Dooner DB On jhe Generalized Contact Stress Thelntemational Conference 011 Mechanical Transmissions ChongqingPR China April 5-10 2001
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Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
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bull
Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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fromllHomel GmbHK1SSsoft gear software has been
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software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
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---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
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COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
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CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
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CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
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NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
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shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
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Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
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bull THIN RLM COATINGSWest Branch Industries
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SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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FOR MORE INFORMATION CONTACTAMERICAN GEAR MANUIFACTURERS ASSOCIATIONbull PHONE (703) 684-0211bull FAX (703) 684-0242bull EMAIL GEAREXPOAGMAO Gbull WEBSITE WWWAGMAORGI bull-
CIRCLEmiddot38 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwge8middotrI9chnologycom bull wwwpowerrransmlssioncom
------ -- ----- IQMII _
Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
_-----------aampAII _
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Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
If you found this article of interest andoruseful pI sa circle
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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i If you would like to rtlJ)Ond
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_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
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INACHIIMACHININGTECHNOLOGY CO
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CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
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HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
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Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
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IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
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Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
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WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
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bull High Performance CNG Hobbingbull Conttnuous Process ~
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PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
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Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
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PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
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GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
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bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
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Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Calculating Dynamic LoadsSizing Worm Gears and
Figuring Geometry FactorsAnswers submitted by Robert ErricheUoGear Consultant GEARTECHjbull Town-send MT and Technical Editor GearTechnology
Questions submitted by Mark H SwalleyUS Navy Pugel Sound Naval ShipyardBremerton WA
0 Wbat is tbe best metbod to measureer calculate dynamic loads in B Ilow-speed spur gear subject to Iloadl rever-sals
A cranes gear train issubject to sud-den load reversal when an emergencybrake suddenlly appUes on the hoistd~m As the drum comes eo a suddenstop thanks to large caliper Ibrakestheel~ectric-powered dfiive baiD colUinuesto rotate The backlash is taken up andthe pinion gear comacts the oppositeace of the drums bulillgear The piiniongear iis on the loutput shah of the speedreducer The limpact is so violent thepinion gear standi bolts snapthe headoff ricocheting around the machineryhouse
The gear train has about 10 times theinertisl of the hoist drum To complicatematters tbe electric motor has time toproduce regenerative Ibraking prior toimpact
A Strain gages are commonly used tomeasure dynamic loads They are a goodchoice because they are readily avail-able relativelyicexpensive and accu-rate for capturing transient loads such asyou describe Computer modeling onthe other hand is accurate only if massstiffness and damping are preciselyknown Damping is especially difficultto estimate and usually requires strain
IRobert Errichellomeasurement on the actual system todetermine accurate values Thereforestrain measurement is the best choice fordetermining dynamic loads in your Iapplication Additionally the mea~ure- I~ents c~ help determine ~ystem damp- Irag which you could use 1n a computer ~model to explore alternative design changes to reduce dynamic loads
0 How shoulld the strain gages be I
placed and how should the signal be I
transmined IIII am Icurrently working out II full j
Wheatstonu bridge arrangement Strain 11
gages win be placed on ~he ends of the19 geaJteetll one on eiither side of the gear tooth base Ithe high tensioneom
j
l
pression areaslThe 38 gages and twodead gages will be dMded into lour le~s o 10 gages iin series The signal Iwilli be transmiHedfrom Shel roSating ~shaft via one of the telemetry-type strain ItrBnsmittellS I
That Brrangement willl reduce the isignal I bout iveltimes ~ve~ the sing~e I
gage lin a 1f4 budge CircUit but Willransmit a constant signal The transmit- iCer sends 500 signalsa second and II j
believe that to be fast enoughtol catch Ithe dynamic event II can correlate the Iresults to strain gages reading from a 1steady state load
QampA is an interactive gar forumSend us your gear design mlnu-facturing inspection or atherrelated questions and we willpass them to our panll ofexperts Questions may bemailed to G Tchnology POBox 1426 Elk Groye Village IL6CDJ9 fixed to (8471 437fi618 orsent vial e-mail to p80plg-tchnoogycom An expandedversion of QampA is online It TIl
G Industry Hom PilI JW twwwglllrtechnologycom
For information on obtainingcopies of the AGMApublicationsmentioned in this column con-tact the association by tlle-phone It (703t 684-0211 by fo It
(703~ 684-0242 or by I-mlil It
techgm bull org
A Your transducer and method of trans- maximum stress However it is eldommitting signals are state-of-the-art To practical to mount gages atthe criticalcapture tooth bending stresses the gages point because of interference with theshould be placed on the root fillet at the matinggears tips You need to decidepoint of maximum bending stress That what it is you wantIsit maximum toothpoint can be found by painting the root bending stress or is it the maximumfillets with brittle lacquer and applying dynamic torque applied to the gears Itloads to the gears The first place to I may be sufficient to measure the torque
j
crack the brittle lacquer is the point of 1 and calculate tooth stresseswwwpoweJrlfliNlsminloncom bull wwwgsarlecllnQlogycom bull GEAR TECHNOLOGYmiddot MAYJUNE 2001 39
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Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
If you found this article of interest andoruseful pI sa circle
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
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Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
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PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
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bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
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GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
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bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
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Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
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Fig 1 - Worm lieu basic dimensions Source A_NSIIAGMA602ZmiddotCQ
Question ubmitted by ChristianWilliamsTexasAampM University College Station TX
(1 How does the desired gear ratiiofor II
worm and worm gear relata tOIthe aelu-all size of the gears For example if Iwanl a gear ratio o 3Ot1Iwhat diameterconstraints are pJaeedi on the gears fortbat Irati01
A Worm wheel diameter is set byrequired load capacity ANSIIAGMA6034-B92 Practice for EnclosedCylindrical Wormgear Speed Reducersand Gearmotors relates worm wheeldiameter to tangential load as follows
Dm = [WII( Cs Cm ev Fe)JI-2i
Where
Dm = mean diameter of the worm wheelCs = materials factor (aceounts for the
worm wheel materials strength)Cm ratio correction factor (accounts
for the gearratio)ell velocity factor (accounts for slid-
ing velocity and vane with diam-eter lead and speed of the worm)
Fe = effective face width of the wormwhee1 (Fe FG or Fe = (23)dwhichever is less)
Wt = tangential loadThe diameter of the worm can vary
somewhat without significantly influenc-
Where
II C = center distance1 d = worm pitch diameter
I ANSlIAGMA 6022-C93 providesguideline that give a practical overview
of worm gear designYou should audit the gearset to ensure
lit meets the design guidelines of ANS]Ji AGMA 6022-C93 and rate the load
capacity in accordance with ANSIJii AGMA 6034-B92 to ensure it has an ade-
quate service factor for the applicationi
i
i Question s[~bmined by Richard Fried- II
man Nichols Aircraft Division Parker
i Hannifin Corp Ayer MA ~r--------------1 I0 Is there a Iclosed-form sOIUUOD for the
Lewis form factor
A No there is no known closed-form
iI
If you did not care for this articla solution However an efficient algorithmf all I bJ If you would like to respond to this or anyor numeric y sOJvmg me pro em JS 1 other article in trul edition of G8
given in AGMA 908-B89 (Ref 1) The1 Tchnologypaasefaxyourresponsatothealgorithm is readily programmed using attention of Randy Stott managingeditorlitthe flow chart given in AGMA 918-A93 i 847-437-8818 or sand a-ma~ messages to
peoptJOgllttechnologycom(Ref 2) Benchmark examples useful for I L JI
ing load capacity ANS1AGMA 6022-C93 Design Manual for CylindricalWormgearing recommends a wormdiameter in the following range
Cl815 S d S QI87S
30 16
lable 1-DellIlO11 of symbols
Worm and worm gear addendumWorm and worm gur dedendumCenter dlstence IClearanc a I
Worm gear mean diameter I
Worm gear outside diameter IWarm gear root diameterWorm gear throat diameterWorm pitch diameterWorm outside diametmiddoterWorm mot diameterWorm gear face widthWorm faca widthlfhread length 01worm)
Full depth of worm threadWorm axial pitch
Somce ANSIAGMA 16022-C9~
validating software are given in Ref-erence 2 and tables of J factor are givenin Reference 1 The algorithm derivesfrom References 3 and 4 0
References1 AGMA 908-B89 Ueomelry Factorsfor Determining the Pitting Re istance andBending Strength of Spur Helical andHerri ngbone Gear Teeth April 19892 AGMA 918-A93 A Summary ofNumerical Examples Demonstrating the
Procedures for Calculating Geometry Factorsfor Spur and Helical Gears Jan 19933 Errichello R ~ Efficient Algorithmfor Obtaining the Gear Strength Geome-try Factor on a Programmable CalculatorAGMA Paper No P 13903 Oct 19814 Errichello R Jn Efficient Algorithmfor Obtaining Ifle Gear Strength Geome-try Factor for Shaper Cut Gears AGMAPaper No P 13905 Oct 1983
hilUs WIllI V11IiIIk
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GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
011bill
11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
IlIIIPI 1M Amon417
722482
3(11
V 1mIll
Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
~ - - V~ -
I r -==--t
100
9
arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
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Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
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We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
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cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
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and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
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COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
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GLEASON IINTRODUCESTIHE-IELIECTRONIC
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Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
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CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
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NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
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Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
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HOB SHARPENINGSERVICE
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SERVICE
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Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
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CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
GEARDESiGINFOCUS _
LoadIIDistriblutionin Planetary Gears
fIrs pp was presentBd-1 me 4111 IWorld COOlfflSS onGfllITiag BDd POWIII lrsnsmis-sion in Pars AfLrch bull
IntroductionTwo- haft planetary gear
drives are power-branchingtransmissions which lead thepower from input to outputshaft on several parallel way iA part of the power is trans- I
ferred loss-free as clutchpower That re ults ill high
efficiency and high powerdensity Those advantages canbe used optimally only if aneven ditribution of load Oil
the individual branches of
Wolfgang Predki Friedrich JarchowandChristof Lamparski
possible today to predict the I
dynamic behavior of such Igears The result of those iinvestigations consolidate thapproximation equations forthe calculation of the load fac-tors KK and KHamp
Parameter Study on LoadFaeurotors
The calculation of the
power is ensured Static over-con~tr~inl manuf~cturi[lg Idevianens and the internal I considers the influence of medyaamies of those transmis- I mentioned disturbances on the
Iion gears obslruct the load masses dynamics The dy- i
balance With die help of COID- namic model underlying the jplex simulation programs it is program is shown in Figure ] i I
EnvirOnmIDtaIIconditiOns I Sizlandlgaomeby of Ute gearing II
Attached mass inertia Genter distanceStiffness of attachment Gear IratioLine load Number of planet gears ISpeed of sun wheel Sum of the addendum modification I
RelativBcircumferential Face widthfdiameter coefficients velocity Number ef teeth of sun i
BaSil helix angle
IGall tooth q1Illity OFP Gfp OfHII j
Pitdllolerame ohhe planet carrier
Bearing eccentricityBeariillg clearance of planat gears i
~ L-A_ng__I_e_Of_IP_O_S_jtj_O_n_Of_th_middot_e_PI_a_ne __t_g_e_ar_s~ I
operanonal dynamic behaviorof a planetary gear stage is done willi the 3-dimensionalirnulation program SIM-
PLEX which was developedin an earlier research project(Ref 2) The program is able
to describe all mas e within Ithe transmission with sixdegree of freedom each and i
Table 1 Parameters censidered on Ihe dynamiC snnulation
Tooth corractionGrowllinglip modificationtongl addendumteeth
I~illl~ynmic modelio1elpianelLIY- ar IIlge 11-lmIIY-nl elioa
Afterwards the masses are I Prot DrAnlllinked to the bearings and to ~olfgangIIPledki _th f d b di Ii the head 0 the chair 0 mechani--e _oulLallon -y arscrete cal components industrial andelastic sheck-absorbing ele- auromolive pltrwer rrl1JlfmLrsonaJments Table 1 quotes the the Ruhr University Bochum iocat-
ed in German) There QFe 16assls-lanlS employed allhe chairour 0whom perform research 011 planr-tary gear INJnsmissionr The
The single clementsare research focuses 011 load dislTibu-tton analysts gearing modific(llionlemperallLre calculalion and technt-cal design
parameters which were con-sidered on ihe dynamic simu-
IProf em DrAngIfriedrieb Jarctiowis Ihe former head oj tn chair 0mechanical components industrialand Q141omolivepower Iransmissionat the Ruhr Ulliversity Boehumlocated 11 GermQJl
lation
combined in nine differenttypes of planetary gears forwhich the parameter studygives th required load fac-tors The planetary gears arecategorized according to thedesignarions oflhefirst col-umn of Table 2 Thus forexample a transmission witha sun gear smiddotllaft and 8 hous-ing-fixed intemalgearreceives the de ignationSlHl That rransmi sion
Dr-InglChrismf Lamparskiiiis the head 0 th dqxmmelflorresearrh and developmen 0hydraulic components 0Schwaebische HuetriTrrwerke GmbHill Bad ScltuJJenried G nntm
This paper Is based on his dOCloraltransmissions provide the dissertation
version forms the basis for thparameter variation Ali other
_____________ IGiEARIDESIIGN FOCUS
Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
I i I II u ~ bullbull os
H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
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Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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The Crown Power Train with its remarkable experience in gearsproduction has developed a CNC gear inspection machine tor
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arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
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Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
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Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
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i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
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STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
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STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
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- Competitive Prices-Relap amp Replating Service
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New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
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and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
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IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
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A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
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CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
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HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
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RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
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shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
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Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
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SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Table 2-Collstrnctioll design 01 SlIl and ring
I
-
Var Description Scheme Var Description Scheme
SII Sun gearI 33 Hl Housing-fjxed ring gear Sm
I I
I
S2 Sun wheel with middotff]-middot H2I
Ringl gear with internall I rbnircurnfarential lengaging curved-toothengaging curveli-tooth gear couplinggear coupling
S3 Sun wheel with internalengaging curved-toothgear coupling ~
14
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H3
S2HI1 S2Hi2 S2H3
S3H3
Ring gear witllflangeconnection rlh
11
100
Fig4--LOId fllctor KyK depedmg on tha Imllr of planel11e8B Iand onthe canler dlstan1 8 shown for me engagement aflun and plaoet gear
1~ __ ~~~--~~--~ ~~~ __ ~
30 ~ eo 70 80 110
~~ II Imml - ~
I~~----------~-----------------bull uus
KK uf---~r--- =~=J125
12
1181t~-===--1015
--VIIS1H1~5bull II iMwn~
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11
S3H1 S3H2IFlgl-TyPlllof planetary gear IJInsmissionl
IKK
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722482
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Fig 5-Loadl factors ~Kdepending DOtbe Iratio from face width b to diem-Ilerd of Ibe Slln wheelinfluences of the examined sented for a basic S1HI tran ~parameter field mission according to Figure
lnjluenceson the load 2 The indicated values of thejaetors KyK The following load factors apply to the trans-results were achieved by a mission specified in theparameter study with the pro- respective picture The loadgram SIMPLEX It shows the factors achieved by transmis-
sionsof other geometry ortype of constraction can bedetermined by approximatingequations contained inReference L The results applyto gears of DIN quality class 6
generally valid tendencies thaia modification of the singleparameter accordingto TableI has on the tooth load condi-lions as mentioned aboveFill 3-ilnfluncl of thlll lin load wand of Ibe clnllmferemjllli spoodl von
11111Iclol product KyIK in the engagement of Iun lIndl planet gau Those tendencies are repre-42 MAYJUNE 2001 bull GEAR TECHNOLOGY wwwgrsahflorogycom bull wwwpowerrlsmlssioncom
bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
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_-----------_1 GEAROESIGNFOCUS _
121181UI
KKl1411211
111111081041(12
r- bull T-middot 300 NrnlI
Vr-- T-400INrn V-r- T -500Nm V
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arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
v 8tH-tKl1m_m
110E -287 200 Nmn
2 e 1 e
Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
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i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
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bull TECHNICAllCAlENIDARII ------------
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May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
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June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
-
PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
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AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
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bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
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Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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bullbullbullbullbull _IGEAR OESIIGN FOCUS II _All rolling bearings indicate a i from DIN quality class 4 Thebearing clearance of class eN housing-fixed ring gear of the
FiguJt 3 shows the mJlu- basic version S 1HI causes aence ~f the specific load w for I partial adjustment of the planetdifferent peripheral speeds v gear in reference to the ringon the dynamic behavior of gear which results in a morethe transmission favorable face width load dis-
The distribution of the I tribution Accordingly the val-load on several planet gears ilues of the factor KH~ of thepermits a higherthroughput of engagement planetring gearpower Figure 4 shows the i are lower than those of theinfluence of the associated Ii engagement of sunplanet gearincreasing static overcall- Figure 8 shows an increasestraint and the influence of the I of tl1e factor KH~ill the S IHIphase position of the engage- version which depends on thementsat the circumference of I number of the engagements ofthe coaxial gears dependent t sunplaner gearon the number of planet gears I Approximationequations
Figure Shows theeffect I 0 the actolroduct KyKvof a changed face width b on Dnd thefaclor KujI An irnpor-
the value of the load factors I tant result ofthis research proj-KyKv The basis of aJJ calcula- I ect is approximation equationslions is a constant line load w i for the determination of thewhicb corresponds to an I load factors ISKv and KHpincrease of the outside torque Detailed information is givenwith rising face width The I in Reference Iimprovement of the dynamic I Testingbehavior with an increasing A system of coupled inho-face width does not result mogeneous non-linear sec-from the modified geometry end-degree differential equa-but from the risen load level
The quality of gear pro-duction is crucial for the levelof the dynamic excitations inthe transmission Both thetotal pitch variation Fp and theindividual pitch variation Ipindicate a dear influence onthe load facto
Influences on the loadfactor KBIlA misalignment ofthe axles causes a system-dependent inclination of thegears For that reason anincrease of the effective toothtrace variation fH13 can gener-ally be expected Figure 7shows the dependence of thefactor KHP on the quality ofthe tooth trace angle variationfA13bull IDI both engagements of(he planet gear a significantrise of the factor KHI3is to beobserved already starting
tions describes the dynamicbehavior of an idealized plan-etary gear The solution of thatsystem of differential equa-tions provides the displace-ments of tile geometricalcen-ters of tile sunplanet gearsand of the planet caniersinthe plane of transverse sec-iOD Acomparisua of thecal-Ciliated andthe measured axisshift allows for the control ofthe simulation program
The measurements aretaken at the self-adjustingtransmission elements Theirmovements can be registeredwith contact-free working dis-placement transducers Twohorizontally and two verticallyattached displacement trans-ducers determine the mis-alignment of the transmissionelements The mounting
wwwpowIJrtrIJflsmissioncom wwwgearlmiddotschflologycom GEAR TECHNOLOGYmiddot MAYtJUNE 20Ql 43
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The Crown Power Train with its remarkable experience in gearsproduction has developed a CNC gear inspection machine tor
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Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
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Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
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Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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wwwgeartechnologeJlpocomwpowerrtatlamfsslotlcom WWWg9Iut9chnoloflycom GEAR TECHNOLOGYmiddot MAYIJUNIE 2001 45
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
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STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
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STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
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_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
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---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
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INACHIIMACHININGTECHNOLOGY CO
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CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
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HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
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IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
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CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
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Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
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23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
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HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
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Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
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Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
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bull BROACH SHARPENINGbull HOB SHARPENING
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PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
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4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
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arrangement of the displace-mentiransducers can be eenill Figure 9
Reference I comparescalculation and measurementand discovers a good corre-spondence between tile re-speetive values
Notes for the Technica1Desgner
Based on recent findingsof projects concerning loaddistribution in planetary gearsthe following notes for designcan be recordedL With the rising extent of uul-ization of the transmis ionsthe dynamic effects lose orneof their importance Causedby a high Iine load the abilityof self-adjustment of the gearsimproves due to existingdegrees of freedom and due toelasticity The factors KKvand KH~decrease with risingload2 An increasing circumferen-tial velocity on the otherhand shows opposite tenden-cies regarding the load bal-ance High-speed transmis-sions usually show very high
load factors especially whenoperated on low load levels3 Gearing deviations such asFp r and fHIil if telerancedaccording to DIN quality class6 or better only exert a smallinfluence on the dynamicbehavior of the transmissionStarting from DIN qualityclas 6 it is advisable ItO pro--vide crowning orend relief4 Center distance deviationstolerated according to DIN3964 remain without influ-ence on the load factors aslong as there is still somebacklash existing However ifthe backlash is consumed theloads can achieve severaltimes the nominal values5 Large numbers of planetgear increase the degree of
2 e
44 MAYJUNE 2001 GEAR TECHNOLOGY WlfHUlechnologycom ww powerlrsnsmlssloncom
Figli--lioadl factors -tK dapunding on 1he production quality oftb [pitchvariations
14--------------------I 135
13middot
K 125
12
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110E -287 200 Nmn
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Fig i-Load fact_orKJjpdapanden on till quality 01 tooth trIIC8 angle varia-lion IIHHIIshownl for the ling Bllemen a sllnlplanet gearalld plaDellii ng geu
30 110
bull [nwnll70
Fig B--Factar Ksp d~pending en lbe number of planl1 gean 111p11 and on tilecanter distance abullsltawnl forth engallm8n~ of sun nd Iplanef gell r
RIrIeoIItranav81M sectJon
Fig ~ection of the S2H2test tr nsmislIioll Thellloai1ion of lbe displilcement tnllllllucelS IS marllied by amIWl
static overconstraint of thetransmission Inorder [0 selectthe number of planet gears Iltegain at load carrying-capacityas a result of power branchinghas to be compared W the 10 -es resulting from increaseddynamic excitation6 The load factors KyKv ofspur gear transmissions can beup to 10 higher than withcomparable helical gearing
middot traasmissions
I ~~~een~~~~e~i size on the load distribution-
11 or more precisely on the loadfactoJS KyKv and KH~-could
middot be determined 0
~
I
bull ReferencesI Lamparski C Simple equa-I lions for determining the load
i
Imiddotincrease in light weight plane-tary gear transmissions FinaJ
i report on research projecti SIIIV Forschungsvereinigung
Antriebsteehnik FrankfurVMain 19942 Winkelmann L Load dis-tribution in helical planetarygear transmissions series ofinstitute for construction bull
issue 87~3 Ruhr UruversiUilj Bochum ]987
I1-----------I ~M~i If you did not care for thisI article cirde --
i If you would like to rtlJ)Ond
1 to this Dr any other article in1his edition of Gar TecIrJaqw
please fax your to thej atIBntion of Randy Stoa man-i aging adiIor It847-cJNI818 or
send amp-mill mtII8geamp toj ~com--1
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wwwgeartechnologeJlpocomwpowerrtatlamfsslotlcom WWWg9Iut9chnoloflycom GEAR TECHNOLOGYmiddot MAYIJUNIE 2001 45
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
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46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
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TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
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PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
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GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
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Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
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Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
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Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
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Provides actual overballpin measurmenof any helical orgear or splin WiLU t-
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Plan our visit to tile sllow months in advainceat Shaw Central
wwwgeartechnologeJlpocomwpowerrtatlamfsslotlcom WWWg9Iut9chnoloflycom GEAR TECHNOLOGYmiddot MAYIJUNIE 2001 45
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
I till Us DIIIk
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_ CIRCLE 1fl i - ~_-o_-_
46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
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~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
-
PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
bull TECHNICAllCAlENIDARII ------------
May 7-11-AGMA Training Scbool forGear Manufacturing Basic CourseRichard 1 Daley College Chicago ILClassroom and hands-on training in gearnomenclature principles of inspection gearmanufacturing methods and the basics ofhobbing and shaping $650 for AGMA mem-bers $775 for non-members Contact SusanFentress by telephone at (703) 684-0211 or bye-mail atentressagmaorg
May Hi-1S-PC AppUcations in Parallel program director by telephone at (414) 227-Axis Gear System Design amp AnaJysis 3125 or by e-mail at rgalbersuwmeduUniversity of Wisconsin-Milwaukees Centerfor Continuing Engineering EducationMilwauleee Wl Course for engineers andother people who specify use or design gearsDr gear drives Provides an understanding ofparallel axis gear design and uses the com-puter program Powerilear for analyzingparameters $1195 Contact Richard Albers
and lils made in AJMERICA
June 11-l5-AGMA 1raining School forGear Manufacturing Basic Course See
rd_es_c_ri_Ptl_O_li__an_d__c_o_nt_a_ct_in_fo_rm__a_ti_on_U_li_derMay 7-11 listing-----
I till Us DIIIk
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_ CIRCLE 1fl i - ~_-o_-_
46 MAYJUNE 2001 bull GEAR TECHNOLOGY w gufeChnologycom bull wwwpowett nsmlsloncom
AIW Systems Co announces that it is now amanufacturing source ot spiral gear roughingand finishing cuttsrs and bodies
I
We also can manufacture new spiralcutter bodies in diameters of S through 12at present
AIW can also supply roughing and finishingcutters for most 5-12 diameter bodies
Whether its service or ma_nufactunng con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise
NEWI Straight Bevell CuttersRoyal Oak Michigan 48067
Tel (248) 544-3852middot Fax (248) 544-3922I I I II
May 21-23-Koepfer Fundamentals ofParallel Axis Gear MaollfactoringPheasant Run Inn and Resort St Charles L Seminar for entry-level gear-manufacturingpersonnel covering gear nomenclature basicmathematics and information on gear nob-bing shaping inspection and other manufac-turing topics $650 Contact Koepfer AmericaLLC by telephone at (847) 931-4121 or byfax at (847) 931-4192
May 21-24-Gleason Basic Gear Funda-mentals Gleason Cutting Tools Corp LovesParle IL A fOIlI-day series of lectures for peo-ple seeking a basic understanding of geargeometry nomenclature manufacturing andinspection $895 Call (815) 877-8900 visitwwwgleasoncom Dr send e-mail 10getcgleasoneom
June 6-9-Macmne Parts 2001 Shang-haiexpo Shanghai China Exhibition willinclude new specialized pavilionfor gears GearChina 2001 the International Gear TechnologyExhibition for China Exhibition will presentmachine parts including chains fastenerssprings and powder metallurgical productsContact Business amp Industrial Trade Fairs Ltdby maiI at Unit 1223 bull HITEC I TrademartDrive Kowloon Bay Hang Kong by telephoneat (852) 2865-2633 by fax at (852) 2866-1770or (852) 2866-2076 or bye-mail atellquirybirjcomhk
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
GET YOUR FREE LISTINGS IN THE GEAR TECHNOLOGYCD-ROM BUYERS GUIDE
(See the following category pages You MUST fill out the form to get yourFREELISTINGS in our FIRST-EVERCD-ROM directory of the gear industryWell mail 14000 copies with our NovemberDecember 2001 issue andhand out copies at Gear Expo 2001)
STEP 1-CONTACT INFORMATION (This is how well get in touch with you if we have any questions)Name Title _
STEP 2-COMPANY INFORMATION (Please be careful This is what will appear in the directory)Company Name _
Address _
Address 2 _
City State Postal Code Country _
Phone Fax _
STEP 3-CHOOSE YOUR LISTING STYLEo $95 Enhanced Listing with Active Hyperlink (CD-ROM users will be able to click on your Web address to automati-
cally bring your Website up on their computer screens)
o Charge my Visa MasterCard or American Express Exp _(authorized signature) _
STEP 4-REQUEST INFORMATION ABOUT ADVERTISING ON THE CD-ROMThis first-of-its-kind complete directory of the gear industry is also a great opportunity for you to demonstrate howyour company stands out as one of the industrys leading suppliers We have several advertising options on the CO-ROM Just check below to let us know youre interested in more information
Yes Im interested in advertising on the 14000 CD-ROMs Send me information abouto A 18-page black-and-white VIPS ad (Very Important Products and Services) Only $795
o A full-page full-color ad in the directory Only $1995
STEP 5-FILL OUT YOUR CATEGORIES(SEETHE FOLLOWING PAGES)
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001PLEASE CONTINUEC-TO THE NEXT PAGE
THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
-
PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
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CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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THE GEARTECHNOLOGYCDmiddotROM BUYERS GUIDE FORMCompany Name _
Gear Cutting Machineryo Bevel Gear Cutting Machineso Broaching Machineso Gear Cutting Machineso Generators Herringboneo Generators Spiral Bevelo Generators Straight Bevelo HobbersHobbing Machineso Rack Millers amp Cutterso Shapers Gearo Spline Hobbing Machineso Spline Milling Machineso Thre~d Worm amp Flute Millerso Other Gear Cutting Machinery
Gear GrindingFinishing Machineryo Bevel Gear LappersTesterso Burnishing Machineso Chamfering Pointing amp Rounding Machineso Oeburring Machineso Gear Grinders Crossed Axiso Gear Grinders Parallel Axiso Gear Shaving Machineso Hard Gear Finishing Machineso Honing Machines (Hard Finishing)o Rack Grinderso Spline Grinding Machineso Worm Grinderso Other Gear GrindingFinishing Machinery
Gear MeasuringTesting Machineryo Bevel Gear LappersTesterso Gear Inspection Machines Analyticalo Gear Inspection Machines Functionalo Testers Computer-Controlledo Testers Double-Flanko Testers Hob amp Wormo Testers Hypoid amp Straight Bevelo Testers Involuteo Testers Lead amp Involuteo Testers Miscellaneouso Testers Pitcho Testers Rolling amp Redlinerso Testers Single-Flanko Testers Soundo Testers Tooth Spaceo Testers Universalo Other Gear MeasuringTesting Machinery
Gear Forming Machineryo Gear Roll-Forming Machineso Spline Roll-Forming Machineso Other Gear Forming Machinery
Miscellaneous Gear Machineso Bevel Gear Quenching Presseso Cutter InspectionSetting Machineso Cutter Sharpeners (Including Hob Grinders)o Other Miscellaneous Gear Machines
Non-Gear Metal Cutting Machineryo Automatic Screw Mach Multiple Spindleo Automatic Screw Mach Single Spindleo Automatic Screw Mach Swiss Typeo Boring Mills Horizontalo Boring Mills Verticalo Broaching Machines Horizontalo Broaching Machines Verticalo EDM Machines
o Grinders Cylindrical Plaino Grinders Cylindrical Universalo Grinders Drillo Grinders Formo Grinders Internalo Grinders Jigo Grinders Surfaceo Grinders Threado Grinders Tool amp Cuttero Grinders Universalo Keyseating Machineso Lathes Chuckingo Lathes Combination
(See also Turning Centers)o Machining Centers Horizontalo Machining Centers Verticalo Milling Machines Horizontalo Milling Machines Verticalo Mills Jigo Saw~ Band Horizontalo Saws Band Verticalo Turning Centerso Waterjet Cutting Machineso Other Non-Gear Machinery
Heat Treating and Related Equipmento Austempering Equipmento Batch Furnaces Atmosphereo Batch Furnaces Vacuumo Brazing Equipmento Continuous Furnaces Atmosphereo Continuous Furnaces Vacuumo Cryogenic Processing Equipmento Flame Hardening Equipmento Fluidized Bed Heating Equipmento Gas Nitriding Systemso Induction Heating Equipmento Laser Heating amp Welding Equipmento Ovenso Stop-off Paints amp Coatingso Other Heat Treating or Related Equipment
Metal Forming Machineryo Powder Metal Presseso Press Brakes Hydraulico Press Brakes Mechanicalo Shears Hydraulico Shears Mechanicalo Stamping Machineso Other Non-Gear Metal Forming Machinery
Miscellaneous Non-Gear Machineryo Automatic Chuckers Multiple Spindleo Automatic Chuckers Single Spindleo Coating Equipmento Coordinate Measuring Machineso Filtration Equipmento Injection Molding Machineso Lapping Machineso Laserso Special Machineso Other Miscellaneous Machinery
Gear Materialso Bar Stocko Cast Irono Gear Blankso Plastic Resinso Plastic Stock Formso Powder Metal Materials
o Steelo Other Gear Materials
Cutting Toolso Broaches amp Broaching Toolso Cutter Bodies for Bevel Gearso Cutting Tools Miscellaneouso Cutting ToolsBlades for Bevel Gearso Hobso Keyseat Cutting Toolso Shaper Cutting Toolso Shaving Cutterso Spline Roll-Forming Rackso Other Gear Cutting Tools
Fixturing amp Workholdingo Arborso Chuckso Colletso Modular Fixtureso Tool Holderso Other Fixturing amp Workholding
Gages amp Measuring Instrumentso Gages amp Measuring Instrumentso Master Gearso Plug Gageso Ring Gageso Thread Gageso Other Gages amp Measuring Instruments
Grinding amp Finishing Toolso Chamfering Toolso Deburring Toolso Diamond Wheelso Dressing Diamondso Grinding Wheelso Other Grinding amp Finishing Tools
Miscellaneous Tooling amp Supplieso Camso Coatingso Coolantso EDM Tooling amp Supplieso Filtration Equipmento Heat Exchangerso Index Plateso Injection Moldso Lubricants Cutting amp Quenching Oilso Other Miscellaneous Tooling amp Supplies
Gear Manufacturing Serviceso Bevel Gear Manufacturingo Broachingo Custom Gear Manufacturingo Gear Forging Serviceso Gear Grinding Serviceso Gear Hobbing Serviceso Gear Honing amp Burnishing Serviceso Gear Lappingo Gear Shapingo Gear Shavingo Stock Gear Manufacturingo Other Gear Manufacturing Services
Heat Treating Services (Commercial)o Age Hardeningo Aluminum Treatingo Annealingo Austempering
PLEASECbullbullbull
CONTINUEFAX ALL THREE PAGES TO (847) 437-6618 BY MAY 15 2001DONT FORGET TO CALL PATRICIA FLAM FOR ADVERTISING INFORMATION YOUR CUSTOMERS
bull- bull ~- kr
Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
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wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
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INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
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Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
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Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
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CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
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Midwest Gear ICOrp2182 E AurorallRd
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Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
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IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
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wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
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PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
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HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
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PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
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CIRCLE 154
MAAG PARTS AND SERVICE
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GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
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Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
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Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
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Company Name
D Black Oxiding LOOSE GEARS OPEN GEARINGD Blast Cleaning Gear Type Min Dia Max Dia DPModule QualityD Boronizing o Aerospace GearsD Brazing o BreakdownEmergency SuppliersD Carbonitriding o Cast Tooth GearsD Carburizing o Coarse Pitch GearsD Cryogenics D Face GearsD Die Quenching D Fine Pitch GearsD Flame HardeningD Hot Oil Quenching D Forged GearsD Induction Hardening D Ground GearsD Ion Nitriding o Helical GearsD Laser Hardening o Herringbone GearsD Nitriding o Hypoid GearsD Nitrocarburizing o Internal GearsD Normalizing o Marine GearsD Plasma Carburizing o Medium Pitch GearsD Press Quenching o Miniature GearsD Salt Bath Nitriding o Mining GearsD Sintering o Miter GearsD Steam TreatingD Straightening o Noncircular GearsD Stress Relieving OPinionsD Tempering o Plastic Gears CutD Vacuum Treating o Plastic Gears Injection MoldedD Other Heat Treating Services o Powder Metal Gears
o Punched Gearso Racks
Consulting Services o RatchetsD CAM Services o Ring Gears (BevellD Gear Design Consulting o RotorsD Gear Engineering Consulting o SegmentsD Gear Failure Analysis o SerrationsD Other Gear Consulting Services o Skived Gears
o Spiral Bevel GearsServices for Gear Manufacturers o Spline ShaftsD Calibration Services o SprocketsD Gear Coating Services D Spur GearsD Gear Finishing Services D Straight Bevel GearsD Gear Inspection amp Testing Services D Timing PulleysD Hob Sharpening D Worm WheelsD ISO 9000 Consulting D WormsD Metallurgical Testing D Other GearsD Shot Peening Blasting amp BeadingD Tool Coating
Please indicate measurements in inchesmm and provide pitchmodule range (ie 4middot20 DP)D Tool SharpeningD Other Services for Gear Manufacturers Please indicate AGMA DIN ISO or other Quality standard (ie AGMA 12)
GEAR DRIVES YOU MANUFACTURE amp SELLSoftware Drive Type Max Ratio Min Ratio Max hp Min hpD Custom Software D Bevel Gear DrivesD Gear Design Software D Combination DrivesD Gear Inspection Software o Cycloidal DrivesD Shop Management Software D Differential Gear DrivesD Other Gear Software o Epicyclic Gear Drives
D Gear (Shift) Transmissions
Training amp Education D Gearboxes
D We Are a CollegeUniversity D Gearheads
D We Provide a Gear School o Gearmotorso We Are a Research Institution o Harmonic Driveso We Are a Trade Association o Helical Gear Driveso Other Training amp Education o Herringbone Gear Drives
o Miter Gear Drives
Used Machineryo Planetary Gear Driveso Shaft Mounted Reducers
D We Sell Used Reconditioned or o Speed IncreasersRefurbished Machine Tools D Speed Reducers
DistributorsManufacturing Reps D Spur Gear DrivesD Worm Gear DrivesPlease list the product linesbrand names that D Other Gear Drivesyou distribute or representNOTE To better serve our readers some entries andor categories in the Buyers Guide may be edited for length or content at the pubmiddotlishers discretion
FAX ALL THREE PAGES TO (847) 437-6618 BY MAY 152001
THE GEAR TECHNOLOGYCDmiddotROM BUYERS GUIDE FORM
IILL BE LOOKING FOR YOU ON THE CD-ROM BUYERS GUIDE CALL (847) 437-6604 TODAY
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
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GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
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CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
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PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
_-------------IPRODUCTNEWS-------------New Name for Gear Software
fromllHomel GmbHK1SSsoft gear software has been
renamed NORA Transmission Softwareand is being marketed by Hornet OmbHa German company
KlSSsoft was originaliy developedtOT internal use by Kissling amp Co aSwiss gear manufacturer In 1999 theprogram was combined with another
software package Himware Except forthe name NORA is identical to thatK1SSsoftHi17lware package
NORA Transmission Softwareincludes calculation modules for gearssprings tie rodstransmi sian elementsshafts and bearings The gearing can becalculated according 1[0 the most currentAGMA ISO or DIN standards fOf spurgears bullbevel gears worm gears and more
preci-ion through diaITIDnd
INTRODUCING PCD REINFORCINGFOR DIRECT PLATIED DRESSERS
For more infonnaliol1 contact HornetGmbH by mail at Seewiesenstr 90 D-73329Kuchen Germany bylelepbone at (49)7331-98-16-46 by fax at (49) 733198-16-47 or bye-mail at inollOmet-gmhhcmn
clnIe 327
Faik Inlroduces IDriva line wiUlIilexible Configurations
The Falk Corp of Milwaukee WIintroduced Drive One a line of medium-torque gear drives willi multiple mount-ing options and drive ccnfigorations
The new line of drives introduced inMarch can be mounted from any of thehousings six sides The drives can be COIl-
figured for use as general-purpose parallelhaft drives and as right-angle drives or
they can be used as shaft-mounted drivesmixer drives or alignment-free drives
Dri ve One gear drives come ill foursizes with torques ranging from 150000Jb-in to 5001)00 Ih-in (17000 Nm to
56000 Nm)For more information visit wwwfalk-
corpcom
We will design build and Quaranteefromvour gear summary charts gear dressers forReishauer SPA and Fassler IDSA Systems--Direct-Plated or Sintered-8ond Single- orDouble-Sided Dressers
WE also producegear dressers formealon CNC
81Phoenix-UebhenIUingelnbergl Pfauterbull Oerlikon-Opalbull Hoefler Kurthbull Kapil Nilesbull Sampu1ensiJiI- Mikron Maagbull Csepell
We oHer OUI customers Highest Accuracy- Fastest Delivery
- Competitive Prices-Relap amp Replating Service
cirde328
New SmsIII-FootprintInduction Machine
Welductlon Corp of Novi MJ intro-duced its Flexscan induction hardeningmachine a compact heat treating systemcomplete with controls and tooling forless than $]00000
The new model can induction hardenandtemper parts up to 13 long
The Flexscan comes with a built-inolid- tale power supply in II variel) of
power and frequency combinations Italso includes II quench cooling system
511 MAYJUNE 2001 bull GEAR TECHNOLOGY bull wflllurtlChnologycom bull wWlpOlsrjransmluIOncom
Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned
DistribvIH by~
DRIKAISERgear dressers are the best value available
SLMunsonamp Company
401 Huger St Columbia SC 29201PIlon 1-8110-115-1390middot Fax 1--81J392HI507E-RJlliI infatitslmuMoRcom
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
---------------- --------
- - -------------------
and heat potentiometerFor more information contact
Welduction by telephone at (800) 798-3042 by fax at (248) 735-282] bye-mailat weldnwelductioncom or 00 theInternet at wwwwelduclioTlmm
drde329
New Wind Turbine Unit fromICinciinnali Gear
The Cincinnati Gear Co ofCincinnati introduced a 15 megawattwind turbine gear unit for use in windpower generation applications
The new unit is rated at 166megawatts power and has a calculateddesign life of 20 years Features includeart integrated oil sump an electric motor-driven lubrication pump high capacityfiltration and visual inspection ports forall gear me hes
The geartlot bas an input speed of 20rpm an output speed of 1440 rpm and a ratioof 721 AU gearing meets AGMAlAWEA921-A97 and GerrnanisCher Uoyd standardsfor wind blrbine geaibolles
For more information contact TheCincinnati Gear Co by mail at 5657Wooster Pike Cincinnati bullOH 45227 bytelephone at (5[3) 27]-7700 by fax at
(513) 27[-0049 or bye-mail at industri-alsalescintigearcom The companysWebsite is at wwwcinligearcom
drele330
TIl MIl v1IIiIIl If you found this c~ of interest andorutefuI plea ~
If you lid not care for this column ~
If you would like to respond to thil or anyother articla in this edition of 6eTechnology plelse fax your response to theatl8ntion of Randy Stott managing editor at847-437-6818 or send e-mail messages to~Nrtechnologycom
Avoid Gear Failure and Save Thousandsof Dollars in Repair Costs
Analysisand lroWIlen gears fail unless the root cause offailure is identified they are likely to failrpnand again and again Br~ak this wastaruI circleof faJlureattend this seminarand - howto eliminategear failures at yorfllilities
Hands-On TraininJwi ampiled Gearsf
For more il1fortnationI 00-597-5460
WANTEDMORE ACCURACYMORE EXPANSIONMORE VERSATILITYLONGER LIFEAND LESS COST
LeCOUNT line12 DewiU Dr - PO Box 9501- White IRiver Jet VT050011 USA
11 1800116416713 OJ 18021296-2200middot Fax (8021296-6843 E-mail IIecDuntsoverneSWebsite httplfwwwleclluntcomincludes producCspecificationsl
wwwpowrlmiddotrilnsmissioncom bull Wwwgearlechlologycom EAR TECHNOLOGY MAYJUNE 200 51
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
COMPONENT GEARMANUFACTURING
Literature available from TheCincinnati Gear Company pro-vides informal ion covering itsfacilities and expertise in com-ponent gear manufacturingincluding bobbing and cuttinggrinding turning boringmilling and inspection Thebrochure includes product pho-los and specifications as wella manufacturing capabiliue
CIRCLE READER SERVICE 1
INACHIIMACHININGTECHNOLOGY CO
Global EJ(pet1isfJFor AllApplications
OUf new Corporate Profilebrochure showcases he ma-chines tools and applicationsthat achis Trademark RedRingmiddot products offer inBroaching Gear Making RollForming and Hobbing
Centaet our sales departmentfor more lDformation
(810) 263-0loo orsalesnachimlccom
CIRCLE READER SERVICE 1M
GLEASON IINTRODUCESTIHE-IELIECTRONIC
IGUIDE SIHAPiERSmall-lot helical gear produc-lion will never be the same withthe New GP300 ES Revolu-tionary Electronic GuideSystem Users of the GP300 ESGear Shaper can increase theirehipmaking time by eliminatingthe need 10 change guides fornew workpiece leadsFor more information contactThe Gleason Worksi 16-473-1000 rCIRCLE REAJ)ER SERVICE iN4
gllDl ~ UUllrHIIlIlUU All loDfURIiD
1tI~t -iflb ml PQURII 11MtulIT
~rAjrii IlIj mHUUU l1-li IIlI 11bull01 un_
GUASON CUnlNGTOOLS ICORPORATIION
A full color catalog showing beproduct capabilities of our world-wide and Loves fark Illinoisfacilities We manufacture high-speed teel and carbide bobsshaper cuners shaving cuttersbevel blades form cutters CBNwheels and lhinlilm coatingsHeat-treat resharpeningandrecoating services are availableGleason CuttingToots CorporatioDTelephone 815-877-8900E-mail gctcglelJsoncomCIRCLe 1IIEADERSERVICE fI~
GROUND GEAIRSPECIAUSTS
Crown Power Train a leadingmanufacturer of gears and trans-mission parts with 20 ReishauerCNC gear grinding machines andremarkable experience in geardesign and production can satisfyall yOW gear requirements at areasonable cost and on limeCrown Power Train SJi1Tel 0039 ()30 7156530Fax 0039 030 7069035E-mailcrowncrownitWebsite wwwcrownitCIRCLE READERSERVICEllf7
HIGH SPEIEOGIEARIINGfaidield Manufacwrings 6-pagefull-color brochure highlightsour capacitie and machinerydedicated 10 producing premi-um quality gears for your highspeed gear application Teethand form grinding peeifica-tions as well as product listingFairfield competitive advan-tages also li ted
Fairfield Mllnufacturing(765) 772-4000
salesfalrlieldmfgcomwwwfhlriieldimfgcom
CIRCLE READER SERVICEII252 MAYJUNE 2001 bull GEAR TECHNOLOGY bull WWwl1uflechnologycomww powerlransmluioncom
AUSTEMPERINGIMIPROViES MATERIAL
TOUGHNIESSOur S-page brochure is an infor-mation-packed guide to theAustempering process bull a highperformance heat lreatment forductile iron gray iron and steelfor improved toughness wearresistance and fal~gue snengthLearn how to boost product per-formance and reduce costsCaliJ Applied hoce s Iac734-464middot2030 01 vi itbttplwwwapplledplOCfSScomCIRCLE RElaquoII)ERSERVICE 1169
NEAR~NET GEARSPresntes 8-pageoolor brochuredjscu=[Jle companys fGifgillgcapabilities equipment and forgingplants The Iiterarure also high-ligltts Presrite Bessemer divisiona near-net gear manufacturingfucility and identifies industriesserved and ru~tomerbenefitsPresrite Corporation366S East 78111 StreetCleveland 0844105middot2048Phone (216) 441-5990Fax (216) 441middot2644[middotMaill infQpmriteiomWeb Site wwwpresrUecomCIRCIEREADERSERV1CE ~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
-
PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
LITERATURE
INDUCTIONI FIXTURESThe LR-PAK data heet de-scribes induction lift rota te fix-tures useful for heat treatingparts such as transmission ODraces 1D CltlIlIS hubs spindlescv joint and gears LR-PAKsare completely assembled andinterconnectedAjax Mllgnethennrc Corp1745 Overland AvenueWarren 08 44482800-547-1527middot Fax 330-372-8608E-maD ajaxsalesajaxmagcomw-II~II1aj(UmQgbullromCIRCLE READER SERlICEIItI
ICALL fOR PAPERSGear Technology is looking forgood technical material for ourupcoming issues We need arti-cles on gear gri~ding powdermetal gears gear workholdingplant automationenvironmen-tal i uesand quality standardsOf course we are alway on thelookout for gear design manu-facturing and inspection arti-cles no matter what the subjectSend for our free writers guide-lines or visit our Websi~e atwwwgeartechnologycom todownload a copyOIRCUE READER SERVICE 12118
11M HEARTLANDITW Heartland Model 3500Gear Analyzer is designed foruse in the gear Iaboratory or onthe factory floor It is suitablefor either process inspection orfinal inspection Measures com-posite run out size nicks toothaction lead and taper Measure-ment accuracy in microns
C[RClE READERSERV1CEn~
SELLOEARS ONUNEThe POWBT Transmission HomePagelM i the Webs leadingdirectory of power transmis-sion manufacturers and suppli-ers Hundreds of buyers visitwWIVpowertronsmssioncomeach day to find the right manu-facturers for their jobs Call(847) 431-6604 to find out howinexpensive and effective Inter-net marketing can be Mentionthis ad and receive a FREBbonus page of advertising withyour orderl
CIRCLE READER SERVICE ~1
CIRCLE fia
powflrrransmlssloncommiddot wwwgelrechllologycom GEAR IE
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
-
PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
I CLASSIFIED-
SERVICE
HOIB SHAiRIPiENllNGIINDEX TECHNOLOGIES
c -AGMA ~lll~ ~Ia~sAAIndex~~o-Helical- - - 11 - Skivillg
~ijo -Carbide-un to 1125 NDP calpacity-recoatingl amp stnipping of allcoating types
-tool performance analysis-rspld turnaround
Index Tecihnologies Inc21m lorain Road Fairview ParklOhio 44126
~Phon8 44O-895-46lIIHOBS) Fax 4AIlmiddot331-1li6 I
Email gallencomsncom I
IIEIJ WANTED
RollsmiddotRoyce Gear Systems a Isader In the aero$pece power gena ration industy currently has anopeningi lor a skilled Gear Grinder 11 our scenicmountain site in Park CityUtah
Ideal applicant will have both 100 D and geargrinding and clitting experiance and willbe abletoperform own sst-u ps Must have 4+ years prioruperience wilh Gleason machines and witll I
shapers and hobbers AeroSJIlce or sLmUafcloseIolera nee work is B plus i
Rolls-Royce offers en excellent medical denIalvision and401[kl plans and 91 positive open-dooratmosphere thaI supports contin uous learning andimprovement To begin your rewarding career withour team send your lesume to
HROrollsmiddot ravcegscomor fax to (4351amp47middot2728RolI$-Roy~e is an Eqal Opportunity Emplover andvBlues dive~sity in ths workplace
Rael-Line Classified I minimum $310 Additionallines 145 per line (II line per inchj Display ClassifiedJ minimum IX-S700 31--$650 per msenion6X-$6IS per insertion Addilional per inch IX-S2lOlX-$225 per insertion middot6X-$215per insertionGear T~cIutology will SCI Itype 10 advertisers layout ordesigna classified ad al no extra charge hyment FullJraquooymenl IIW5I middotIICOOIIlp8IIY classified ads Send checkdrawn in US funds 00 a US bank orVisalMasteCardlAmcrkllll Express number and expira-ioo doe 10G~ar Technolagy PO Box J426 Elk GroveVill eo IL 60009 igmcy Comntis5Ioo No agencyoommissioo on classified ads rbleriab IlQdIlne Adltmusl be reeeived by 1M 20di of ib monlh two IIOOIhsprior 10 pubfication AaIptance Publi~her reserves theright to accept or reject advertisements at his discretion
SERVICE
Hilrth ColUlplingsStandalldland Custom
Fast DeUvery - Great IPricesVisit our website for data sheets
httpwwwtae-Inccom
~Ti - ~ middotN-C CONNmiddotCON INCRANSATLA TI f h_ _
1436 Collingswood Dnva Rockford IL 611103Tel815middot282-6070 bull Fax 815~282-4656
CIRCLE1~
GIEAR TOOTH IGRINDINGSpur bull IHelical
bull Heningbone Iwitb groove)Capacity up to 63 00
1 0IP16 face
AGMA ICertUication InspectionlDelivery 101 Mee~toDr Requiremants
Midwest Gear ICOrp2182 E AurorallRd
Twinsburg 10H 44081IPhone330gt415-4419
Fax 330middot425I86001
Direct your inquiries toRon lfIumphrerGeneral Manage
ronlmwgearcomOIRCUE 1iP-
1--1INTEIASTATE TIDDL CORP - CLIEVEe OHIIIO
CUSTOM ENGINEERED ampMANUFACTURED CU1T1NG TOOLS
ESTABLISHED 1960
FORM REliEVED PIIOIUE GIIIlIJNDMIWNG CU1TEiRS
IGEARSHAPER 5HAVING ItUTiERSAll CLASSES OF IHOBS
55S0UDI CARBIDE CARBIDE TIPPED
WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAlRS lOR MampM INSPECTIONS
ICIINTACT US FOR IIQIJOTE TiIlDAYI
wwwilaquolerststetoolcorcomTel216middot671middot1017 IF~ 216-671-5431
GEAR TOOTHGRINDING SERV~CES
bull Cost effective gear tooth grindinglspecialists
bull Gmiddotear manufacturers are our onlvcustomers
- Prototype and pmduction quantitiesbull Capacity to 275 PO 35 II)I PmiddotAble to match delivery to your
requirements All service to AGMA standaeds with
Certified Gear Inspection Equipment
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PRECISION GROUND GEARSbull Spur Helicalland Pump ~
Gears to AGMA Class 15IFealuringlhelalest grindingand CNC technology includingbull Relshauer RZ300E Electronic
Gear Grindersbull GleasonTAG 400 CNC8-axis
High Production Gear Grinder Full CNC Multi-axis CylindricalGrinding(Internaland External)
bull High Performance CNG Hobbingbull Conttnuous Process ~
Utilizing SPC and Quality Planningbull JIT Delivery using Innovative
Stodling Programs
800-447middot2392Fa 71H74-t003
~com
PRO-GEAR COMPANY INC- --
23 Dick Road lI)epew NY 14043loll Free 877middot684-3810middot Fax 716-684middot77117
E-mail progearillcaolcom
HOB SHARPENINGSERVICE
Ster Cutter co
bull THIN RLM COATINGSWest Branch Industries
Subsidiary of Star Cutter Co2083 W M-SS Wast Branch MI486611
l-BaB-Resharp 1-888-737-4277Pilon (511) 345-2885 bull FAX (511) 36-5660
CIRCLE 1454 MAYJUNE 2001 GEAR TECHNOLOGY bull WWWgllllrrctlnologycom wwpOllflfulrnilmluloncom
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
SERVICE
GEAR TOOTHGRINOINIG SERV1CESSpUf - Helical- Double Helical
Capacity up to 16lS0_0 1 [I_p 2grStro~keAll ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16l2IGMM Inventory of grinders includesHoner BOO Hofler 11)00 Hofler 1253Supra Hofler 1500 and Hofler NovaCNC 11)00 (Fufiy CNC with on-boardCMM checker]
Kreiiter Gear1ech2530 Garrow St Houston TX 77003IPhone 713-237-9793 Fax 713-237-1209Contact Mr Willie WhittingtonVIsit our Website atwwwkreiter-geanech com
CIRCUE 1~
lndlUction HardeningSpecialists in Toom bV loothIContour Hardenilng of IntemallSpur helical and bellel gearsOur gear hardening equipmentincludes 5 NATGO submsrqedprocess machines and 5 AJAXCNC-controlled gear scanningmachines Tooth by tooth gearhardsninq from 5Dpmiddotl0DIP up to115 tons 200middot diameter
American IMe1a11Treatingl CompanyCleve lind Obio
Phane (2161 01-4492 -Iiax (21611131-15118Web wwwametlClJametJJltnJlIingcam
E-mail ma middotamatiCBlImelBltreatingcom
Breakdown SerVice AvailableCIRCLE $a
Reconditioned Cuttell Bodies$IGuaranteedl Cost Saviings $AW Systems can recondition AWSpiral Bevel Cutter Bodies to 100 like-new condition
Am Systems can sharpen Spiral Beveland StJa[ght Bevell Cutter IBlades Hobsharpeningl salViee also available
Rapid turnaround timeMost sizes available
For information alld quoteplease cnntact us at the following
AWSvstems CDmpany612 EIHarrisanl AveROYII OlLk-gt MJ 48061
IPhone (248) 513852IFax (248)544-3922
HOB SHARPIENIINGbull State-of-the-art eNC sharpening
and inspection machines
bull Wet grinding with frea-cutting CBN ordiamond wheels for Barn fHieH sharp-ening of carbide or high speed steel
bull Optional reeoating andstripping
bull Rush service available
Koepfer America LLC635 Schneider DriveSouth IElgin Il60H1
PhoneB47-9al-4121 IFax 847-931-4192III ~IIIp~(ltknAntA ra msncac am
bull BROACH SHARPENINGbull HOB SHARPENING
bull SHAVING CUITER GRINDINGbull THIN RLM COATING
bull CUSTOM HEAT TREAT SERVICE
PICK UP AN[I DELIVERY IN MANY AREAS
G~easonCUtting ToolsCORPORATION
1351 Windsor Road PO Box 2950Loves Park IlL61132-2850
Phone (8151877-89001Fax (815) anmiddotD264
IHOB SHARPENllNiG(763) 425-5241
HSS amp Carbide up to 5 DiaStraight Gash
Sharpened amp InspectedPer AGMA STANDAHDS
Quick Turnaround
IKORD SHARPENING SmiddotERVmE9530 - BSTH AVENUE NO
MAPlJE GROVEIMN 55369
CIRCLE 154
MAAG PARTS AND SERVICE
CIRCLE 15-7--
GIROUND GEARSbull Precislon Ground Spur or Helical Gears up
12 Inches In Diameter and Achieving up toAGMA Oass 12 Quality
bull Precision Hobbed middotGearSup 10 16 inches inDiameterPrototype to Medlurn Produdiof1 Quantitie~
Honer ZP350 Analytical Gear Analyzer toIMYra Quality
4864 Stenstrom RoadRockford IL 61109Phone (615)874~3948 Fax (815)874-3811
_ 1I)eugear com
Orillinal MAAG Parts for all Grinding Machinesbull Shapirngl Machines (8Mbull Inspection Machines
Swiss Traiinsd Service IEngineersRmiddotepairs to Complete Rebuiilds
bull ICalibrationbull Cemiddotnificationbull IEvaluations
-- - ------
Becker GearMeisters Inc111001423middot2531 li6311 821middot3961 Fax (631 821-3870Q Chicago lIIinois
CIRCLIEuia
FELLOWS I
Gear Measuring Instruments
OEMApp~ovedbull CallibraUon amp CertiflcaUonbull IField Repairs
100 River Street Springfield VT 05156Ph 802-88591760 Fax 802-885-65~9
www ltItileengll7~nnglnc som
CIRCLE US CIRCLE1~ po rtrnml bullbull IOIIcom 1ItI gutlchnololUCOm bull DEAR TECHNOLOGY MAVJUNE 2001 55
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
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Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
Shes working in wearable art fashion His interest was what acquaintedCommissioned last summer to create him wilh Chows work Hed seen her
the dress Chow tomed Wmzder Gears work in Chicago at the Museum offactory and took home a variety of plastic Contemporary Art where he serves onthepans inc]udingtile part wilh the internal museums permanent collection commit-gear spline As she recalls the square tee In spring 2000 he saw three dressesparts starshaped space intriguedlter-~t created by Chow in a museum exhibitadded another dimension Months later Chows new gear dress ~ ==~iinterest endOf
Chowobtaiaed about ] 500 copies of was featured at a fashion show-at unful plein oiraIe the part to make the dress She linkedthe Wmzeler Gear The show was part of the I IlfyoudidnatcerefDr1hisIl1lcIe 56 MAYJUNE 2001 bull GEAiR TECHNOLOGY wWIIIIgllllrteCllnorOtlY-com wwwmiddotpoWIlrtmiddotrsnsmlsslancam
Combining involute curves and bodycurves merging factory and fashionWmzeler Gear has transfonned one of itsproducts into gear haute couture WinzelerGear has created a plastic gear dress
1 was trying to come up with some-thing unusual to create a theme for our60th anniversary party says JohnWmzeler the companys owner and thatrelated to our already successful gear jew-elry campaign
Started in 1997 that campaign was aseries of elegant black-and-white photo-graphs of a fashion model wearing ringsearrings and bracelets-all made fromplastic gears The understated ads gracedthe pages of Auto World Design News andMachine Design
The new gear dress consists of manymany many copies of one plastic piece asmall square part with a star-shaped] inter-nal gear spline The part is used ina gear-clutch assembly which itself is used in anactuator motor forprovidimg lumbar sup--port inautomobile seats
Located in Harwood Heights IL aChicago suburbWmzeler Gear manufac-tures precision-molded plastic gears forthe appliance automotive and businessmachine industries
Wmzeler Gears latest piece of gearfashion was created by a Chicago fashionartist Cat Chow Winzeler describes Chowas an artist whos tryinglD decide whethershes a sculptor er a fashion designer-s-
weighs a 101 on a wom-ans body Winzeler I
estimates the dress weighs about 10 I
pounds-vlrs a littlebit on be heavy side
In addition thedresss weigha limited JC~~u ~
WOIi Ib IUiol Dlodel -its length Chow mig- Ttfllfty[righIlWirmlerllllr1inallytalked about it plUllcpif dna II lip
being a long dress DI_11 plHlIe ptrt Ibl r UII lIIIrmiddot~pld inllmelBut a long dress _( ~would have had structural problemsChow estimates that a long dress mighthave weighed as much 20 pounds ormore the dress would have been tooheavy for its rings to hold together and for Iits wearer to stand up I
It became a short dress Wmzeler saysito creating the dress Chow turned the
square parts so they looked diamond-shaped11urning them allowed her to cre-ate the dre ss V-neckline its front andback V-hemhnes and its V-shaped sleevesShe explains that creating the V-cutsaccentuates the part itself
It made it more interesting to have thepart turned the diamond way Chow saysabout the dress She adds thatmming theparts also broke the fabrics rigidity gavethe parts more depth and made the dress
oompanysanniversary party held Oct 2-0That day the main aisle in WinzeJer
Gears factory became the runway for tilefashion show Professional models woreIbe gear dressmd olber dresses created byChow The dresses included one made ofo-rings and another made of a single [IX)
yard-long zipperWben we do a commission we do not
want to stifle the artists creativityWinzeler says We commissioned her 10
do whatever she wantedSince the party the dress has been
shown at some trade meetings AI-aWinzeler expects to display the dress atupcoming plastic shows Its currently dis-
I played in Winzeler Gears lobby alongwith pictures ofthe gear jeweJry
Like the jewelry the dre S ID-ltly becomepart of a WinzeJer Gear ad campaignWmcZeler has aheady started to work onplans for such a campaign
The campaigns purpose To make surepeople remember who we are Wmzelersays He adds hat whether people likelhecampaign or not they will be talking about itA business-writer friend of mine calls itwomp word-ofmouthpotential 0
more excitingWmzeler says he commissioned Chow
10 create a dress because of his interest in
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~
FerliBfIIlll r iisplinl IDBdliru palmlts all us tllIlBYOur 5111I1I1IIIIUI1l Ioot 8taBmiddotI~tlrB~nlIJIIIIufletaring facilityambind with n UJlmntl~oil nruilIlIIlWI lUllrinig BndBlIgin will uIIyur Bl1Iviu101lur_wrtGtyJa I ling ~UIIIIUIgJmuerioD joll~ _II III trIflJ III~IH arln III bullbull
wwrrYI II_II WI tBn hll
Perry It1thnlIlogy Corporlltilln lO Box 21 291dultII lIk ROlld
New BItID11I CT OBOS--~