JULY 2010

Analyzing BEARING Failure Insights Into Ultrasonic Cleaning

SITE SAFETY TOOTH TIPs
Company Profile: Surface Combustion, Inc. Q&A: Trace Hill Loudon Industries, Inc.

IN COLLABORATiON WiTH

Booth# S9453

Booth# N6930

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options.

Features

Heat Treat Processes for Gears

By Nicholas Bugliarello, Biji George, Don Giessel, Dan McCurdy, Ron Perkins, Steve Richardson, and Craig Zimmerman

Different heat treating processes impart particular qualities in your gears. In this article Bodycote provides an in-depth understanding of the available

24

Company Profile: Surface Combustion, Inc.

By Russ Willcutt

Founded on the basis of a proprietary technology, this company has continued to lead the way in developing cutting-edge thermal processes and equipment.

Analyzing Bearing Failure

By Steven Katz

26

No one wants to experience bearing failure, but close study of all the factors involved will allow you to help avoid the associated costs and downtime in the future.

Insights Into Ultrasonic Cleaning

34

By Ed Sullivan

As is the case with any manufacturing process, choosing the right ultrasonic cleaning method can mean the difference between wasting time and making money.

JULY 2010

Booth# N7112

Resources
MACHINES

MARKETPLACE

57 60

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

8 20 22 53 64

ADVERTISER INDEX

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Site Safety
Terry McDonald One key to implementing a successful safety program is to make sure that its as convenient as possible for everyone involved, including those who enforce it.

JULY 2010 | VOLUME8 / NO. 88 Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: Send address changes to Gear Solutions magazine, P.O. Box 1210 Pelham AL 35124. Publications mail agreement No. 41395015 return undeliverable Canadian addresses to P.O. Box 503 RPO West Beaver Creek Richmond Hill, ON L4B4R6. Copyright 2006 by Media Solutions, Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage-and-retrieval system without permission in writing from the publisher. The views expressed by those not on the staff on Gear Solutions magazine, or who are not specifically employed by Media Solutions, Inc., are purely their own. All "Industry News" material has either been submitted by the subject company or pulled directly from their corporate web site, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to editor@gearsolutions.com.

William Crosher What is the true definition of surface finish, and how can the extremes of roughness be minimized? A deeper understanding will help overcome challenges.

Tooth Tips

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

Trace Hill, president

Q&A

Loudon Industries, Inc.

American Gear Manufacturers Association

In this section the premier supporter of gear manufacturing in the United States and beyond shares news of the organizations activities, upcoming educational and training opportunities, technical meetings and seminars, standards development, and the actions of AGMA councils and committees. Letter.................................................................................................. 15 Calendar of Events. .......................................................................... 16-17 Association News. ............................................................................ 16-17 News (cont.)/Masthead. ......................................................................... 18 JULY 2010 5

LETTER

FROM THE

EDITOR

David C. Cooper
Publisher

Theres a lot to be said for real-world, hands-on experience, especially in manufacturing. Its critical to any employees professional development, in fact. But there is also a strong argument to be made for developing relationships with academia, which can result in mutually beneficial research and allows a company to stay plugged into the latest technologies and methodologies being taught in college labs and classrooms. Surface Combustion, Inc., realizes the importance of this connection and has identified a number of ways in which to capitalize on it. One involves the aforementioned R&D, and another is an engineer in training program in which recent university graduates enter into an intense training period, learning their job from the ground up while also providing the company with fresh perspectives. We believe youll enjoy learning more about this innovative company in this issues profile. As for our features, Bodycote has provided a team of expertsNicholas Bugliarello, Biji George, Don Giessel, Dan McCurdy, Ron Perkins, Steve Richardson, and Craig Zimmermanto address Heat Treat Processes for Gears. This is an in-depth and informative article that describes various types of heat-treat technologies so that youll be positioned to choose the right approach for your particular application. We are also pleased to continue our longtime collaboration with ASM International's Heat Treating Society, producer of the HTPro eNews online publication (visit www.asminternational.org to subscibe). Steven Katz of Emerson Bearing shares his thoughts on Analyzing Bearing Failure, pointing out that understanding all the factors involved can help you to avoid unnecessary downtime, and Ed Sullivan provides Insights Into Ultrasonic Cleaning that will help you save both time and money at the end of the manufacturing process. In his Site Safety column, Terry McDonald ponders ways to simplify safety-related procedures in your production facilityunderstanding that the easier you make something to accomplish, the more likely people are to get onboardand William Crosher provides us with a true definition of surface finish and how extremes of roughness can be minimized. Trace Hill, president of Loudon Industries, tells the story of how his company came into being, and how solid, longstanding relationships with his customers and vendors alike have helped the company weather the most recent economic downturnand others before. We all realize the importance of these relationships, of course, but its a good thing to be reminded of occasionally. In closing, wed like to congratulate the AGMA on the success of its recent Strategic Resources Network (SRN) event held at GE Transportations headquarters in Erie, Pennsylvania, reported in this issue by Web Communications Manager Mary Ellen Doran. The 50-plus attendees toured the facilities and enjoyed a host of expert speakers: including Ed Hall, Sr., who is general manager of mechanical technologies; Bill Hali, senior product manager of GE Off Highway Product Management; Suraj Devadiga, product manager of Wind Gearboxes; and Steve Gerbracht, who is manager of GE Locomotive Systems. Suren Raomanaging director of the Gear Research Institute (GRI) at the Pennsylvania State University also addressed the gathering, along with Jim Kane of Elwood Quality Steels. The AGMA is already planning upcoming events, which you can read about in upcoming issues of Gear Solutions magazine.

Chad Morrison
Associate Publisher

Russ Willcutt
Editor

EDITORIAL

Kassie Hughey
Assistant

Brad Whisenant
National Sales Manager

SalES

Teresa Cooper
Manager

CIRcUlaTION

Jamie Willett
Assistant

Kassie Hughey
Assistant

Jeremy Allen
Art Director

ART

Michele Hall
Graphic Designer

CONTRIBUTING WRITERS
Nicholas Bugliarello William P . Crosher Biji George Don Giessel Dan McCurdy Terry McDonald Ron Perkins Steve Richardson Craig Zimmerman Steven Katz Ed Sullivan

P . O. Box 1987 Pelham, AL 35124 (800) 366-2185 (800) 380-1580 fax David C. Cooper President

Published by Media Solutions, Inc.

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

6 gearsolutions.com

Chad Morrison Vice PresidenT Teresa Cooper Operations

Trends, Data, and Industry Developments

Okuma Tech Center and Hartwig Host SME Chapter

the largest machine tool and metal cutting distributors in North America, Hartwig owns and operates eight office locations covering 14 states. Visit online at [www.hartwiginc. com].

Solar Atmospheres Launches New Web Site

The Houston chapter of the Society for Manufacturing Engineering (SME) held their monthly meeting and enjoyed a facility tour last May at the Okuma Tech Center. SME members and guests attended a presentation by Hartwig, Inc. Team leader Gary Frick and Bryan Newman, THINC product specialist, gave a presentation on the THINC control, illustrating its open architecture and plug-and-work capabilities. Attendees were given the opportunity to see the Okuma machines in action. Machine demonstrations included the VTM-80Yb, five-axis vertical lathe with M tool functions, the Multus B400-W multi-function mill/turn machine and an MU-400 VA 5-axis trunion-style machining center. The highlight of the evening was the automated Okuma oil-coupling cell, which produces API couplings for oil patch and runs with minimal operator intervention. On hand were representatives from members of Partners in THINC who answered questions from attendees and presented product demonstrations on workholding, industrial lubricants, tooling, and gauging. Bob Waters, tech center coordinator, observed that many of the guests were first-time visitors to the center and that they were exceptionally engaged and took the time to speak with and ask questions of the engineers and operators. SME Member Ed Gordon stated, It was a most enjoyable learning occasion. Okuma has turned the partnership concept intowhat appears to be a very effective organization of resources capable of beneficially resolving any customers problem or need. Okuma America Corporation is the U.S.-based affiliate of Okuma Corporation, a world leader in the development of computer numeric controls (CNC) and machining technology founded in 1898 in Nagoya, Japan. Learn more at [www.okuma.com]. For half a century Hartwig has been focused on helping its customers control their manufacturing destiny and keeping manufacturing in the United States. One of

Over the past year Solar Atmospheres has developed a new Web site focused on reinforcing its leadership position in the vacuum heat treating industry and further demonstrating its unique capabilities and services in vacuum heat treating, vacuum brazing, vacuum carburizing, ion nitriding, vacuum gas nitriding, annealing, sintering, and many other areas. With the changes in the current economy, technology and the company expansion, Solar was proactive in improving the current site, adding many new features to assist existing and new customers and providing significant information about how their heat treating needs can be addressed. Goals for the site centered around three areas: 1) to offer greater access to information about company capabilities and services for those needing heat treating; 2) to facilitate greater interactivity with existing and new customers in order to further improve levels of service and; 3) to provide greater insight into the performance and quality standards. The companys heat treating capabilities and service pages highlight the wide range of expertise it can offer companies, and the customized approach Solar Atmospheres takes for every project. The new site will offer a live chat capability to allow a person to communicate quickly with customer service or technical support personnel. Another feature is a new media section where technical videos, white papers, industry articles, and news are available for viewing or downloading. A quality section where visitors can peruse the quality programs, certifications, and policies that help make Solar Atmospheres a leader in the heat treating industry. Founded in 1983, Solar Atmospheres has a metallurgical testing laboratory, a full-time

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

gearsolutions.com

corporate metallurgist with 30 years of experience, and a comprehensive R&D engineering department. For more information contact Tim Williams at (215) 721-1502 x548 or timw@ solaratm.com. Go online to [www.solaratm. com].

New Release of RomaxDesigner for Transmission Design

Another enhancement is the improved third party links and development into time domain based analysis software such as Ansys and integration to other dynamic analysis packages. Romax is also pleased to announce the launch of a new online customer support portal. This will ensure that RomaxDesigner users receive the highest level of technical support from their in-house team of support and application engineers, as

well as a direct link to the developers who work closely on improving the software every day. Visit [www.romaxtech.com] for more information.

New Appointments at Excel Gear

Excel Gear, Inc., announces the appointment of Denis Bermingham as the manager of manufacturing engineering and special projects and William Bill Powers as the companys mar-

Design engineers are increasingly presented with more challenging scenarios, especially given automotive industry trends towards more efficient, quieter, and higher performing vehicles. The need for confidence in simulation technology has never been greater. With Romaxs latest release of RomaxDesigner R12.7, it delivers such confidence by offering a more in depth level of analysis than ever before. The new edition includes advanced capabilities such as accounting for thermal expansion, test duty cycles, improved NVH gear whine analysis, and gear root stress prediction, as well as many other features and improvements. When designing transmissions, thermal expansion is a major factor and users can now account for this when using RomaxDesigner which now calculates the thermal expansion for all components, enabling users to visualize how this affects the whole system at the same time as considering clearances, deflections, and preloads. This new capability considers the thermal expansion of shafts and bearings, as well as housings, planet carriers, and other imported finite element components. Testing of transmissions is an essential part of the design process, and with RomaxDesigners new capability for test duty cycle generation users benefit from massively reduced rig testing times. RomaxDesigner now generates a test duty cycle from road load data with condensed damages. This matches for both gear contact, gear bending, and bearing damages within one single duty cycle, thereby reducing the need for additional testing time. The software can now accurately perform a root stress analysis, predicting root stress due to gear mesh loads and system deflections. A critical gear performance parameter, users can now calculate this without having to resort to time-consuming and specialized FE analysis. Again, another huge time saving. As the demand for NVH technology grows Romax have improved the usability and robustness of all RomaxDesigner NVH functions, increasing the ease of use for customers.

JULY 2010

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Bill Powers

Denis Bermingham

keting manager. Both appointments were made by company president N.K. Chinn Chinnusamy, who noted that they were made as the result of the companys recent growth and anticipated expansion into new market segments. Bermingham brings a strong engineering background in metalworking and machine tool building to his new position, as well as an extensive knowledge of metallurgy and heat treatment. He will oversee Excels manufacturing engineering and special projects, as well as continue the companys ongoing implementation of lean manufacturing strategies. He brings 30 years of manufacturing and machine tool experience to Excel Gear, having spent the majority of his career at Ingersoll Milling Machine in the manufacturing engineering, assembly, engineering, and prototyping departments. He has a degree in industrial technology and will be responsible for the various manufacturing functions at Excel. I joined Excel Gear to become part of the technical/manufacturing environment here, he says. We can offer customers innovative solutions with excellent quality and value. Im very excited to be part of this team. Powers brings 30 years of experience in the gear and machine tool business to Excel. Formerly an account manager, project manager, and supervisor of customer training with Ingersoll, as well as other metalworking/automation systems firms, he has handled various sales, marketing, and customer relations functions, giving him a well-rounded perspective on the dynamics of the industry. He has a degree in business administration and will oversee all the marketing and business development for Excel. Chinn has structured a first-class company at Excel, he says, supplying engineering-based products, brought to market by a very highly-skilled and dedicated team. All customers receive the highest quality possible, backed by service and application assistance thats second to none. Its a great working environment, and I look forward to the challenges of our changing markets. For more information call (815) 623-3414, e-mail sales@excelgear.com, or go to [www.excelgear.com].

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Conference Spotlights Precision Measurement/Inspection

The Coordinate Metrology Society (CMS) announces that the organization has chosen 25 technical white papers to be presented at its annual Coordinate Metrology Systems Conference (CMSC) from July 12-16, 2010, at the Grand Sierra Resort

located in Reno, Nevada. White paper submissions were received from metrology experts and scientists from research laboratories, universities, and leading manufacturers in North America, Eastern and Western Europe, India, and Japan. Topics to be presented are as diverse as the speaker roster and include aligning

the James Webb Space Telescope, Airbus A320 Aircraft Assembly Line Alignment, and other applications of photogrammetry, articulating arms, laser radar, laser trackers, 3D scanners, 3D vision systems, and more. The CMS is also pleased to announce its 2010 keynote speaker, Thomas A. Greenwood, program director of the A350XWB Leading Edge Spar at Spirit AeroSystems, Inc. Additionally, the conference will host four workshops covering the Coordinate Metrology Certification Initiative, 3D Imaging, Gage R & R, and GD&T. CMSC 2010 also features an exhibit hall showcasing portable measurement systems (PCMMs), software, accessories, peripherals, and service providers supplying the needs of the industrial measurement marketplace. More than 35 exhibitors participated at last year's conference, where ideas, concepts, and theory flow freely among the participants. Conference attendees hail from prominent science/research laboratories, educational institutions, and industries such as aerospace, satellite, automotive, shipbuilding, power generation, and general engineering. The Coordinate Metrology Society is a membership of users, service providers, and OEM manufacturers of close-tolerance industrial coordinate measurement systems, software, and peripherals. The society gathers each year to gain knowledge of the advancements and applications of any measurement system or software solution that produces and uses 3D coordinate data. The Coordinate Metrology Systems Conference is an annual event sponsored by the Coordinate Metrology Society. Established in 1984, the five-day conference is held each year at a different location, and attracts visitors from around the globe. CMSC has achieved world renown for its comprehensive program of top-shelf white papers and applications presentations given by industry experts from science/research laboratories and leading manufacturing industries. A full listing of the papers, as well as conference registration information, can be found at [www.cmsc.org].

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American Gear Manufacturers Association

AGMA Strategic Resources Network Tour

A sellout crowd descended on Erie, Pennsylvania, on June 9, 2010, for the most recent event of AGMAs Strategic Resources Network (SRN). Led by Chairman Cory Sandersonvice president of sales and marketing at Koepfer America, LLCthe 50-plus attendees entered the gates at GE Transportation headquarters for a day of dynamic speakers and a tour of the plant facilities in the areas of wind energy, off-highway vehicles, and locomotives. SRN attendees were addressed by four speakers from GE. Ed Hall, Sr., general manager of mechanical technologies, provided an overview of the companywith its 8,000 employees and $3.8-billion budgetand specics about the transportation division. He also discussed GEs Ecomagination which brings together expertise and technologies from a cross section of GE businesses to work toward new energy-efcient, cleaner solutions for industry. Bill Hali, senior product manager of GE Off Highway Product Management, discussed their 45-year history of electric drive systems and current work in the market of AC drive systems for the mining industry. Suraj Devadiga, product manager of Wind Gearboxes, spoke to the current trends and issues in the wind energy industry. Compared to GEs long history in other industries, wind energy technology is relatively new to the company, and he discussed the excitement for the future development in the industry. And Steve Gerbracht, manager of GE Locomotive Systems, gave an overview of GEs 85-year history of building locomotives, also talking about emissions being the biggest factor in todays locomotive technology development. Two speakers from outside GE also made presentations. Suren Rao is managing director of the Gear Research Institute (GRI) at the Pennsylvania State University. He discussed the current activities of GRI, including the Drivetrain Technology Center at the Applied Research Laboratory (ARL). The ARL is the largest single research activity at Penn State, utilizing over 1,200 faculty and students. Some of their current research deals directly with manufacturing: high strength P/M gears for vehicle transmissions; development of near-net forging for increased bending strength; and evaluation of tooth bending strength due to the intensive quench process, DCT. His presentation is available at the GRI Web site [www.gearresearch.org/events.html]. Jim Kane of Elwood Quality Steels discussed the current and new trends in steel consumption and the factors that have impacted the market in the last three years to change the face of pricing trends in the industry. Did you know that Thomas Edison chose Erie as the location for GE to build locomotives, and that they use some of the same buildings today to create their state of the art machines? Attendees learned this and much of the companys history as they walked through the locomotive plant, which recently celebrated 100 years in existence. GE Transportation is the worlds leading manufacturer of diesel-electric locomotives, and the main producer of signaling and control systems. GE has locomotives operating in more than 60 countries. Attendees also toured the wind-energy and off-highway production areas. GE has been developing technologies for the wind energy market, and they

Mary Ellen Doran AGMA Web Communications Manager (703) 684-0211 doran@agma.org JANUARY2010 15

build gearboxes at the Erie facility. Their system is designed for a 20-year lifespan, and technologies are moving forward toward achieving greater efciency. Motorized wheel drive systems are produced in the same facility as the wind gearboxes, and visitors were able to see the many processes and workow at the plant. Attendees had overwhelmingly positive responses after the packed day, and the SRN is already planning next events for the group. If you are interested in attending a future event or would like more information contact AGMA Meetings Manager Madelaine Morgan at morgan@agma.org. Special thanks go to Mike Sirik, Dennis Richter, and Harry Hagen at GE Transportation. This tour marks the last event for SRN Chair Cory Sanderson as he turns the reins over to the current committee vice chair. AGMA would like to send special thanks to Cory for his strong leadership in getting the SRN off the ground and to such a dynamic point.

The AGMA Strategic Resources Network (SRN) provides new and upcoming gear industry professionals from within AGMA membership with a dynamic, educational, productive forum to help participants grow both within the industry as well as the association. These industry presentations address such topics as leadership, best business practices, AGMA programs, and personal development. Meetings are held several times a year, often in conjunction with facility tours. The Gear Research Institute, afliated with ASME and AGMA, is organized to provide and supplement gear-related technological needs by conducting research and development, consulting, analysis, and testing. The institute is a leading proponent of cooperative pre-competitive research that also serves individual companies on request. Founded in 1982, The GRI has conducted many programs in important technology areas.

Calendar of Events
** Event open to AGMA members only. Not a member? Send e-mail to membership@agma.org. WebEx This committee evaluates the design, rating, and application of enclosed helical gear drives where the pitchline velocity exceeds 5,000 fpm or pinion speed exceeds 3,600 rpm.

Whether youre looking for technical education, networking opportunities, or a way for your voice to be heard in the standards process, the AGMA has something to offer you. If you would like more information on any of the following events visit www.agma.org or send e-mail to events@agma.org.
WebEx The committee evaluates special considerations required for helical and herringbone gears used to drive cylindrical grinding mills, kilns, dryers and metal rolling mills.

WebEx This committee evaluates sound and vibration specications and methods as applied to gearing, generally to enclosed gear drives.

Buffalo, NY This committee continues work on the new revision for AGMA 910C90 Formats for Fine-Pitch Gear Specication Data. The committee will also continue its work on AGMA 916-AXX Face Gears with Intersecting Perpendicular Axes.

July

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Marine Enclosed Drives Committee Meeting

20 20

Sound & Vibration Committee Meeting

21

Mill Gearing Committee Meeting

Fine Pitch Committee Meeting

15

Metallurgy & Materials Committee Meeting

21-22

August

5-6

Energy Efciency Committee Meeting

Gear Accuracy Committee Meeting

17
Energy Efciency Committee Meeting

WebEx This committee evaluates gear materials and heat treatment.

WebEx Alexandria Bay, NY As the U.S. Technical Advisory Group to ISO Working Group 2, the committee is currently developing the U.S. position on the revision of ISO 1328-1 Denitions and allowable values of deviations relevant to corresponding anks of gear teeth. The committee also is working on the new revision of AGMA 2002 and an information sheet on rack tolerances.

WebEx

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gearsolutions.com

A&J Engineering www.ajeusa.com

AGMA in India at IPTEX-20

Global Inspections-NDT, Inc. www.global-ndt.ca

Arvin Meritor Commercial Goldenstate Gear & Vehicle Systems Machinery, Inc. www.arvinmeritor.com www.goldenstategear.com The rst International Power Transmission Exposition, which was held

May 20-22, 2010, in Mumbai, India, was aHarrisburg successArea by several measures. Brunkerville Engineering Community College With over 80 exhibitorsincluding some of Indias largest and most Carolina Gear & Components Ltd. www.hacc.edu prominent manufacturers as well as suppliers to the industry, manuwww.cgc-group.net Iowa State University www.iastate.edu facturers of related equipment, supplies, and servicesboth exhibiEaton Corporationtors and the many attendees found new business opportunities that Vehicle Group Klingelnberg AG www.eaton.com www.klingelnberg.com well organized and promoted trade shows deliver. Organized by Virgo Communications & Exhibitions (P) Ltd. owners Anitha Rahgunath, and KTR Corporation Essential Power www.ktr.com Mr. G. Raghu, the show was both attractive and productive. A number Transmission Pvt. Ltd. www.esenpro.com QuesTek Innovations LLC Gears Inof AGMA members exhibited at the show, including Bevel www.questek.com dia, Premium GES Tech Group Energy Transmission, Essential Power, Gibbs Machinery www.gestech.net Renk-MAAG GmbH Company, Supreme Industrial Gear Works, Magtorq, Reishauer, KTR, www.renk-maag.ch and others. In addition to AGMAs exhibiting at the IPTEX show, AGMA President Joe Franklin, Jr., made site visits to several AGMA members such as Supreme Energy Transmission, San Engineering and Locomotive, Bevel Gears (India), Magtorq, and Supreme Industrial Works.

Joe Franklin, center, with Sulaiman (left) and Abdula Jamal of Bevel Gears (India).

Reishauers exhibit at IPTEX.

WebEx

Chicago, IL This committee determines strength and durability rating of spur and helical gears.

WebEx The committee evaluates special considerations required for helical and herringbone gears used to drive cylindrical grinding mills, kilns, dryers and metal rolling mills.

Gear Manufacturing and Inspection: Gain a broad understanding of the methods used to manufacture and inspect gears, and how that information can be applied to the design process. Concordville, PA

Technical Division Executive Committee Meeting

Helical Gear Rating Committee Meeting

Mill Gearing Committee Meeting

AGMA EDUCATION EVENT

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September

14-15

22 21-22
Wormgearing Committee Meeting

28-30

13-15

Gear Failure Analysis Seminar

AGMAs seminar will allow students to examine various types of gear failure, such as macropitting, micropitting, scufng, tooth wear and breakage. Possible causes of these failures are presented along with some suggested ways to avoid them.

Chicago, IL The scope of this committee covers all aspects of cylindrical and globoidal wormgearing, including design, rating, application of enclosed drives and inspection.

Available Year-Round

Online Workforce Education

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

JANUARY2010

17

AGMA Foundations 2010 Annual Campaign Begins

The AGMA Foundations 2010 Annual Campaign will begin soon. Volunteers are making early contact with AGMA members and other friends to provide updates on the foundations activities and extend an invitation for Campaign Champions who pledge by August 13, 2010. We hope that you will join others in support of your industry, and your foundation, says Joe C. Grifn, CEO and president of Grifn Gear and chair of AGMA Foundations 2010 Annual Campaign. The foundation is grateful for all its generous supporters and recognizes them on its Web site and in its displays at Gear Expo and the AGMA/ABMA Annual Meeting. The Annual Campaign funds a variety of programs, including the following examples from 2009:

 A grant to AGMA to videotape the Detailed Gear DesignBeyond Service Factors advanced engineering seminar and format the content to be available in modules online with a study guide and check for learning tests. The online seminar is expected to go live in September of 2010 and will increase the reach of advanced engineering programs to those unable to travel to seminar locations.  A grant to the Gear Research Institute at Penn State to document how to compute transmission-error patterns on tooth working surfaces that are the cause of ghost error tones, thereby enabling manufacturing-source diagnosis of such tones and commensurate accuracy specications. The book will include a complete description of the proven CNC gear measurement meth-

odology required to accomplish the above, as well as numerous examples of successful implementation of the technology.

Excellence in gearing through the advancement of gear science, standards, and education.
Corporate and individual pledges to the campaign can be e-mailed to foundation@agma.org, or you may ll out a pledge form at [www.agmafoundation. org]. Become a Campaign Champion by pledging on or before August 13!

AGMA Leadership
Board of Directors
Jim Bregi: President, Doppler Gear Company Ivan Brems: CEO, Hansen Transmission International Sharon Haverstock: Executive Vice President, Scot Forge Company Richard Kuhr: Senior Application Engineer, ABA-PGT, Inc. Bryan Lammers: Division Manager, Caterpillar, Inc. Jeffrey Lawton: Vice President, Star Cutter Company Gary Lehman: President & CEO, Faireld Manufacturing Co., Inc. Dana Lynch: President, Cleveland Gear/Columbia Gear Gordon New: Managing Director, Ronson Gears Pty., Ltd. Jack Nowlin: President, C-B Gear & Machine, Inc. Bob Phillips: Senior Vice President, Gleason Cutting Tools Corp. Roland Ramberg: President & CEO, The Gear Works-Seattle Kyle Seymour: President & CEO, Xtek, Inc.

Executive Committee

Chairman: Dave Ballard Corporate Manager, SEW-Eurodrive, Inc. Chairman, TDEC: Dr. Phil Terry Metallurgist, Lufkin Industries Chairman Emeritus: Dennis Gimpert President, Koepfer America, LLC Treasurer: Matt Mondek President, Cotta Transmission Company, LLC Chairman, BMEC: Leslie Hennessy VP Strategic Planning & Business Development, Lovejoy, Inc.

Staff

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

Contact the AGMA

18

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

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

www.agma.org gearsolutions.com

siteSAFETY
terryMcDONALD
Member of the ANSI Subcommittee on Gear Safety

One key to implementing a successful safety program is to make sure that its as convenient as possible for everyone involved, including those who enforce it!
IVE BEEN THiNKiNG ABOUT ways that we can simplify our safety systems and procedures. What made me think about this was a conversation I had recently with the owner of a small company concerning his safety program. He was concerned about the amount of time and energy that would be required to maintain the program hed instituted to protect his employees. This really made me start thinking about alternate ways that can be utilized to reduce the amount of time required by an accident, or even just a violation of the safety procedures adopted in a small shop. Most of the owners or managers of small enterprises that I know of want to do the right thing insofar as a safety program is concerned. Due to the busy nature of their jobs, however, finding the time to research the causes of accidents or to explain the importance of established safety proceduresor even punishing the lack of concern shown when established procedures are not followedcan take an extraordinary amount of their time that could otherwise be used to increase sales or production. So how do we help these small shops that dont have the resources to employ one or more individuals to concentrate on the safety program alone? Ive been giving this a lot of thought lately, and I have come up with a few suggestions. Id like to solicit any help you can offer, however, so please contact me at the e-mail address listed at the end of this column if you have any input youd care to share. Here are my suggestions: 1) U  se signage. The signs dont have to be elaborate, or polished. With todays easy to use computer programs anyone can make signs that make your safety concerns obvious and easy to understand. The key, as I see it, is making sure the signs message is clear and that its placed in a spot thats highly visible. The signs should point out the obvious hazard, and the correct way of combating it. Make your signs as concise as possible, because you do not want employees spending lots of time reading it. Its intended to be a reminder, not a trainer. 2)  Provide training. I know, training your people takes valuable time away from the production floor. However, when you consider the time lost when an employee that has not been adequately trained has an accident that results in an injury to themselves or a fellow employee, the amount of time spent on proper safety training is a small loss of production compared to the alternative. 3)  Formal safety manual. Again, I know, creating a proper formal safety manual is a time consuming project, and as I have noted in previous columns it is and should

be an ever-evolving project. There are many Web sites that sketch out the bare bones of a proper manual and offer the information free or for a minimal fee. If you are creating your first safety manual I strongly urge that you do a little surfing online to find these helpful sites. Their help will actually take hours off the time needed to create a proper manual. Dont forget that many of these sites are government sponsored, or belong to government agencies, and if you use and reference them it may go a long way toward helping you in the case of an inspection or even a nasty lawsuit. Remember that this is only new to you. Many others in your position have gone

Most owners of small enterprises that I know want to do the right thing insofar as a safety program is concerned, but theyre already busy due to their primary responsibilities.
through similar processes, and now you can benefit from what they learned along the way. 4)  Create checklists. This may be your biggest timesaver. Every time you have a safety meeting, training session, review orGod forbidhave an accident follow-up, there are certain items that must be covered. It is very difficult if not impossible to remember every item off the top of your head, and very time consuming to have to go through your safety manual in its entirety each time to be sure you covered everything. I therefore suggest that you create short checklists for each of the scenarios that may occur so you can be sure that critical questions are asked and answered. This will really save a lot of time and make your job easier. I hope these suggestions will help you in some way, and dont forget that I would really appreciate your input! Any comments you can provide will appear in a future installment of this column.

Terry McDonald is partner and manager of Repair Parts, Inc., and a member and pastchairman of the ANSI B11.11 Subcommittee on Safety Requirements for Construction, Care, and Use of Gear Cutting Equipment. Contact him at (815) 9684499, rpi@repairpartsinc.com, or [www.repairpartsinc.com].

About the author:

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TOOTHTIPS
williamCROSHER
Author, engineer, and former director of the National Conference on Power Transmission

What is the true definition of surface finish, and how can the extremes of roughness be minimized? A deeper understanding of this concept will help overcome challenges.
THE TERM SURFACE TEXTURE is used to describe the deviations from what is considered as a nominally perfectly smooth surface. The term can be further defined as the repetitive or random deviation of the normal surface that forms the threedimensional topography of the surface. The surface roughness does not follow a true geometric pattern; there will always be a wide assortment of peaks and valleys. These surface variations include flaws, waves, roughness, and the direction of the main surface pattern. In the 7th International Conference of Metrology and Properties of Engineering Surfaces in 1997, gear surface topography can be characterized due to the noise by three parameters that describe the profile undulations. Irrespective of the finishing process the differences are in amplitude, wavelength, and the direction of the undulations. They have a direct correlation with the decibel level. Grinding creates the worst conditions as undulations are produced with the highest amplitude, the longest wavelength, and in a direction almost perpendicular to the path of contact. Conventional honing is used to reduce the amplitude and create a more favorable undulation direction. The surface finish that is determined will also consist of a series of measurements above and below a mean surface line. In the practice of gearing, the gears performance and wear is affected by how extreme the levels of roughness are. With all gear manufacture it is important to minimize these extremes. More than a dozen roughness parameters are specified in ASME B46.1-1995. The arithmetical average of the peak to valley deviations provides the roughness measurement. Compact and battery operated surface instruments of low cost provide the RMS (root mean square average) in microinches. In lubrication the ratio of the fluid film thickness to peak-to-valley surface roughness provides the specific film thickness. In recent times a more popular measurement is Ra, or Arithmetic Mean Roughness Value. In other words, the arithmetic average value of the filtered roughness profile that can be determined from the deviations above the centerline and within a specific evaluation length. Rmax (maximum individual peak-to-valley) dimensions obtained from five sampling lengths within the evaluation length. RzDIN is the arithmetic average maximum mean peak-to-valley height of

roughness using five consecutive sampling lengths over the filtered roughness profile. Rq (RMS) represents the root mean square roughness value that is obtained from the deviations of the filtered roughness profile over the evaluation length. Rp is the single highest peak above the centerline of the filtered profile. Pc is the pak count taken over 10mmof the filtered roughness profile. The peak is only read after the profile has passed through both a lower and upper variable preset threshold. The threshold lines are parallel to the centerline. There is no relationship between gear quality and surface finish in AGMA standards. An AGMA document on gear tooth surface texture (AGMA906A94) is a guide to surface finish. Unfortunately there are still many who do not realize the significance of the surface finish on tooth flanks and believequite incorrectlythat it will be a self-correcting condition. Tests have indicated that the rubbing of any two surfaces reduces the initial roughness by no more than 25 percent. Modern-day surface measuring systems consist of a probe that

The gears performance and wear is affected by how extreme the levels of roughness are, and with all gear manufacture it is important to minimize these extremes.
is powered to move across the involute surface. This probe sends signals to a computerized system that filters and evaluates the topography. The filter selection is critical in obtaining accurate findings. The M1 filter is the filter of choice. The three categories of roughness, waviness, and form can be seen. Some 40 years ago an RC resistor capacitor filter was popular, and it is still in use on older equipment. It is unreliable, however, and results can be distorted. Another important criteria for accurate results is termed the cutoff. Sintered, P/M, and cast iron gears are porous and have a surface with many deep valleys. Gear flank surfaces should be measured in one direction from the tip to the root. The roughness wavelength is generally considered to be 1/20th of the tooth length.

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

About the author:

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Gearing Up Your Business

You speak, we listen, and together we develop solutions to your complex manufacturing challenges. With years of experience in designing and manufacturing gears, CGC also understands the importance of project management and logistics, ensuring on-time delivery of high-quality products made to meet AGMA, ISO, and DIN standards. So give us a call, and well give you a listen.

CAPABILITIES
Gear Cutting Gear Gashing

CURRENT 8m 5m 1.5m 2m

FUTURE 10m 10m 2.8m 4.5m

Carolina Gear & Components Ltd.

330 Pinebush Rd. | Cambridge, Ontario | N1R-1Z6 | Canada

Gear Grinding Machine Turning

P: 519-623-8806 | F: 519-623-4886 | E: sales@cgc-group.net | www.cgc-group.net

COMPANY PROF ILE

Surface Combustion, Inc.
By Russ Willcutt

Founded on the basis of a proprietary technology, this company has continued to lead the way in developing cutting-edge thermal processes and equipment.

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Just five years shy of celebrating a century in business, Surface Combustion is a remarkable company that has remained true to its innovative roots. A manufacturer of thermal systems and equipment, since it was founded in 1915 based on the proprietary technology for which the company is named it has received more than 645 equipment and process patents, been awarded 75 trademarks, and installed some 250,000 thermal systems worldwide. It all began, however, with the advent of the surface combustion process. It was discovered that if you premix fuel gas with air, it provides a hotter flame and better combustion, according to Dan Goodman, vice president of sales. The companys founders also realized that if you pass that flame by heated plates or some type of catalyst in the furnace, combustion was more thorough and the heat of the flame was further increased. So that was the basis of the whole company, which was launched in New York City before moving to Toledo, Ohio. We now have two facilities nearby, with one in Waterville thats devoted to manufacturing and the other housing engineering, R&D, and administration in Maumee. In addition the company has licensed representatives around the world, in countries such as Germany, Mexico, China, Brazil, Argentina, Russia, and Japan. The Japanese company licensed our technology just after World War II, and that relationship is still in place so that we exchange technology and conduct joint R&D projects, Goodman says. With registered trademarks on such lines as Allcase batch integral quench furnaces, Uni-DRAW high convection heating systems, and Trident radiant tube heating systemsjust to name a very fewSurface Combustion is a veritable technology generator, which is basically built into the companys DNA. One outgrowth of this heredity is apparent in its hiring policy. We kind of buck the industry trend in that we like to hire engineers straight out of college, Goodman explains. We have whats called an engineer in training, or EIT program in which young college graduates spend five years learning and applying all the basics of what we do, and how we do it. Theyll actually be involved in commissioning new equipment for our customers, so they really earn their stripes before they begin working in sales or design. We make that investment because our goal is for them to have a complete career at Surface Combustion. Not only does this provide the company with a direct connection to the latest developments in academia, its resulted in a workforce with an average age in the early forties and a median tenure of 16 to 17 years. A significant portion of the companys employees have remained for many decades, including Goodman, who is a product of the EIT program and has been with the company for 30 years. Apart from the equipment it manufactures, Surface Combustion also serves in an advisory capacity, working with its customers to determine the exact thermal system that will meet their needs. We have product lines consisting of ev-

erything from atmosphere to vacuum equipment, continuous furnaces, batch furnaces, and all of the handling and companion equipment thats required such as control systems and auxiliary atmosphere generators. Someone can simply tell us what theyd like to do and we can advise them across technology lines, he says. That allows us to be very objective, and to make suggestions based on their particular application. Having such a broad range of products also helps should one market experience a downturn, since diversification can provide protection from such trends. In addition to automotive, Surface Combustion is also involved in offroad, aerospace, and even government ordnance work such as developing systems for the incineration of chemical weapons. We also provide equipment that carburizes or throughhardens gears, nuts, bolts, bearings, and the like, Goodman says. So that broad range of experience allows us to listen to a customers needs and suggest a number of technologies we believe they should consider, complete with a list of pros and cons for each. During his three decades with the company, Goodman says that hes seen many advances being made, especially in the areas of controls, sensors, and even the material handling aspects of the systems it designs and manufactures. The changes that have occurred in things such as robotics, carbon control, and the types of insulation that are now available are simply astounding, he says, and one of the reasons were so plugged in to these advents is this fresh stream of young minds we constantly have flowing into the company. Its just a great way of keeping us at the leading edge of developments in thermal processing. We always want to be at least two steps ahead of everybody else so that we can provide our customers with the best value possible.

Call (800) 537-8980, e-mail info@surfacecombustion.com, or go to [www.surfacecombustion.com].

To learn more:

Analyzing Bearing Failure

By Steven Katz

No one wants to experience bearing failure, but close study of all the factors involved will allow you to help avoid the associated costs and downtime in the future.

The accurate diagnosis of a bearing failure is imperative to prevent repeat failure and additional expense. Rolling bearings are precision machine elements found in a wide variety of applications. They are typically very reliable even under the toughest conditions. Under normal operating conditions, bearings have a substantial service life which is expressed as either a period of time or as the total number of rotations before the rolling elements or inner and outer ring fatigue or fail. Less than 1 percent0.35 percent specifically (fig. 1) of rolling bearings do not reach their expected life [1].

PREmaTURE BEaRING FaIlURE

When a bearing does fail prematurely, it is usually due to causes that could have been avoided. For this reason the possibility of reaching conclusions about the cause of a defect by means of studying its appearance is very useful. Its most important to correct the causes and prevent future failures and the costs that follow. Most bearing failures such as flaking and pitting, spalling unusual wear patterns, rust and corrosion, creeping, skewing and others are usually attributed to a relatively small group of causes that are often interrelated and correctable. These causes include lubrication, mounting, operational stress, bearing selection, and environmental influence.

GREaSE SERVIcE LIfE

The purpose of lubricating the bearing is to cover the rolling and sliding contact surfaces with a thin oil film to avoid direct metal to metal contact. When done effectively it reduces friction and abrasion, transports heat generated by friction, prolongs service life, prevents rust and corrosion, and keeps foreign objects and contamination away from rolling elements. Grease is generally used for lubricating bearings because it is easy to handle and simplifies the sealing system, while oil lubrication is generally suitable for high

Fig. 1: Examples of bearing failure.

speed or high temperature operations. Generally lubrication failures occur due to: using the wrong type of lubricant; too little grease/oil; too much grease/oil; mixing of grease/oil; and contamination of the grease/oil by objects or water. While we have spoken about a normal bearing service life it is also important to take into consideration the normal grease service life, as the two should be considered together to maximize bearing life. Grease service life is the time over which proper

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Fig. 2: Bearing failure, radial internal clearance.

Fig. 3: The author poses with a range of Emerson Bearing products ( W. Marc Bernsau/Boston Business Journal).

bearing function is sustained by a particular quantity and category of grease. This is especially critical in pump, compressor, motor, and super-precision applications.

you will create too much preload, and if the fit is too loose you will create too little preload, which may allow the shaft to rotate or creep in the bearing. Check for proper diameters, roundness, and chamfer radius. Avoid misalignment or shaft deflection. This is especially critical in mounting bearings that have separable components such as cylindrical roller bearings where successful load bearing and optimal life are established or diminished at installation. Be aware of radial internal clearance (fig. 2): It is critical to maintain the proper R.I.C that was established in the original

MOUNTING aNd INSTallaTION

It is critical in the mounting and installation process to pay strict attention to the following: Use of proper tools and ovens/induction heaters. Use a sleeve to impact the entire inner ring face of the ring being press fit. Verify the shaft and housing tolerances. If the fit is too tight

We MANUfACTURe THe BeST, eASieST TO SeT Up GeAR DeBURRiNG MACHiNeS ON THe MARKeT.

 Automatic Air Operated door Operator Interface PLC controls Filtration system  Work Light inside hood

 Additional deburring heads  Automatic air chucking  Thermostatically controlled heating element.

SERVICES

Our customer service response time is second to none. We offer contract deburring of your gears, along with rebuilding all makes and models of gear deburring machines. Chamfermatic is a full-service supplier to the industry. Contract Deburring Grinding wheels Machine rebuild Carbide Deburrs

We OffeR BOTH MANUAL AND fULLY AUTOMATeD MACHiNeS.

In addition our machines are portable, and carry a Two Year Limited Warranty.

Osborn brushes

7842 Burden Road Machesney Park, IL 61115 Tel: 815-636-5082 Fax: 815-636-0075 CHAMFER96@comcast.net

www.chamfermatic.com

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STANDARD FeATUReS:

OpTiONAL FeATUReS:

SOUND
Hiss Buzz to Roar Crunch

OTHER INDICATORS
Small Bearings

CAUSES
Raceway, ball or roller surfaces are rough Resonation

Loudness and pitch change with speed

Poor Fit Bearing rings deformed Vibration or raceways, balls or rollers Dust/Contamination Scoring of raceways surfaces Scoring of balls or rollers Dust/Contamination

Felt when bearings is rotated by hand

Hum Clatter Screech/Howl Squeak Squeal Rustle Growl Quiet Fizzing or popping Large sound pressure

Disappears when power supply is shut off Noticable at low speeds, continous at high speeds Occurs mainly on Cylindrical Roller bearings Sound changes with speed. Goes away temporarily with lubrication Metal to Metal spalling sound. High pitch Generated irregularly due to grating Sound quality remains the same even if speed changes Continous at high speeds Generated irregularly on small bearings Large sound pressure

Electromagnetic sound of motor Bumping in cage pockets due to insufcient lubricant Large radial clearance. Poor lubrication Small clearance. Slipping of tting surfaces Dirt or raceways, ball or roller surfaces are rough Scoring on raceway, balls or rollers Bursting sound of bubbles in grease Rough raceway, roller or ball surfaces Raceways, rollers or ball deformed by wear Large internal clearance due to wear

Table 1: Bearing failure modes.

design. The standard scale in order of ascending clearance is C2, C0, C3, C4, and C5. The proper clearance for the application is critical in that it allows for the challenges of:  Lubrication. A proper film of lubricant must be established between the rolling elements. Reducing internal clearance and impeding lubricant flow can lead to premature failure.  Shaft fit. It is inevitable that there can be a reduction in the radial internal clearance when the bearing is press fit.  H eat. In the normal operation of bearings there is heat produced that creates thermal expansion of the inner and outer rings. This can reduce the internal clearance, which will reduce the optimal bearing life. in the larger application may change. If loads become too high, overloading and early fatigue may follow. If they are too low, skidding and improper loading of the rolling elements occur. Early failure will follow in each situation. Similar issues arise with improper internal clearance. The first sign of these issues will be unusual noises and/or increased temperatures. Increased temperature. Bearing temperature generally rises with start up and stabilizes at a temperature slightly lower than at start up (normally 10 to 40 C higher than room temperature). A desirable bearing temperature is below 100 C. Noises. There are typical abnormal bearing sounds that indicate certain issues in the bearing application. While this is a subjective test, it is helpful to know that a screech or howl sound generally indicates too large an internal clearance or poor lubrication on a cylindrical roller bearing while a crunching felt when the shaft is rotated by hand usually indicates contamination of the raceways (table 1). Operational stresses in the applications can impact bearing life as well. It is critical to isolate vibrations in associated equipment as they can cause uneven running and unusual noises. As for selection, we have designed an online Bearing Detective that will help choose the perfect bearing for your application. Whether youre an OEM or MRO client, Emerson Bearing will track down the bearing that is required. By asking a few simple questions pertaining to type of bearing, width, dimension, style, cage material, inner race, and mounting along with any other identifying features such as shields, seals, or SnapringOD, the Bearing Detectiveavailable on our Web site, listed at the end of this articlewill identify the required bearing for your application.

OpERaTIONal STRESS aNd SElEcTION

It is generally the exception to find a bearing that has been improperly designed into an application. However, factors with-

ENVIRONmENTal INflUENcE
Even with the best design, lubrication and installation failures will occur if the operating environment is not taken into con-

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sideration. While there are many potential issues the primary ones are: Dust and dirt, which can aggressively contaminate a bearing. Great care should be given to use proper sealing techniques. Aggressive media or water. Once again, sealing is primary. The use of specialty type seals is recommended such as pump mechanical or labyrinth-style seals that do not score the shaft. External heat. The ambient operating temperature mandates many choices in radial internal clearance, high temperature lubricants, intermittent or continuous running, and others that affect bearing life. Current passage or electrolytic corrosion. If current is allowed to flow through the rolling elements, sparks can create pitting or fluting on the bearing surfaces. This should be corrected by creating a bypass circuit for the current or through the use of insulation on or within the bearing. This should be an inherent design consideration in applications such as wind turbines and all power generating equipment.

4)  Fersa Bearings. Roller Bearings: Failure Diagnosis. 2009. 5)  Koyo Bearing Corp. Rolling Bearings: Failures, Causes and Countermeasures. Catalog No. 322E. December 1995. 6)  NTN Bearing Corp. Products and Technology. Care and Maintenance of Bearings. 2009.

about The author:

Steven Katz is the president of Action and Emerson Bearing. Call (800) 225-4587 or visit [www.emersonbearing.com].

CONclUSION
To sum up our conversation, the first step in the overall prevention of bearing failure lies in the consideration of bearing technologies that are most suitable to the application with regard to specifications, recommendations, maintenance strategies, fatigue life, and wear resistance of the bearing in relation to the application. That said, premature bearing failure within a proper application is typically attributed to one or more of the causes discussed lubrication, mounting, operational stress, and bearing selection or environmental influencewhich can and should be corrected in order to avoid future bearing failures and additional cost.

REfERENcES:
1)  FAG Bearing Antriebtechnik 18 from 1979. 2)  Barden Corporation. Machine Tool technical bulletin for Engineering and Lubrication. 2010. 3)  FAG Bearings Corp. Rolling Bearing Damage. Publ. No. WL 82 102/2 December 1997.

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t o n I U s l t tra h g i s s

n i a n e g l C c i n o
By Ed Sullivan

As is the case with any manufacturing process, choosing the right ultrasonic cleaning method can mean the difference between wasting time and making money.

In

If youre looking for ultrasonic gear-cleaning equipment, you may begin your search by logging onto the Internet or poring over spec sheets in hopes of finding a solution that best suits your needs. Chances are you may quickly become mired in a blizzard of technical terms and specifications about transducers, frequencies, harmonics, and chemistry that leave you more confused than informed. Although the superior benefits of ultrasonic cleaning may perfectly suit your needs, how do you unravel the complexities and obscure language of the technology when all you really want is a plug & play solution? In the vast majority of cases, the users who can benefit from ultrasonic cleaning systems should not need to possess an in-depth knowledge about the science behind the technology. Nor should they have to agonize over choices in product design, accessories, or the chemistry of cleaning solutions used with ultrasonic systems. Ultrasonic cleaning is a very productive technology, but I believe that sometimes the equipment manufacturers are overly enamored with the technical aspects of it, making decisions more complex than necessary, says David Arata, whose experience with the field of ultrasonics goes back over 40 years. He warns that while choosing any process equipment is hardly a no-brainer, it should not be overlooked that in many instancesparticularly with inexperienced usersit is critical that the equipment marketer assist that user in making the best equipment selection.

PlUG & PlaY SOlUTION

Arata has a U.S. patent as co-inventor of a unique ultrasonic cleaning generator circuit, and he has traveled and met with engineers from around the world to understand their requirements for precision cleaning. He is now a marketing and technology executive with Omegasonics where he supports the test lab, the facility where new or demanding applications for ultrasonic equipment are proven according to specifications that are established with prospective customers who are uncertain about their particular application. Rather than dazzling such customers

Fig. 1: Parts are loaded into an ultrasonic cleaning machine.

with technological information theyll probably never need again, Aratas laboratory approach calls for thoroughly and accurately determining the customers needs and expectations, which he feels are vital to simplifying their selection processes and making their ultrasonic cleaning solution truly plug & play friendly. We have extensive experience in quite a few industrial sectors, he says, including aerospace, gear manufacturing, food and pharmaceuticals, military, and utilities. Yet in virtually every sector the customer may have unique or changing production processes that must be addressed for them to fully realize the productivity and quality benefits of ultrasonic cleaning. As examples of diverse working environments Arata cites U.S. Navy ships that use a range of portable ultrasonic cleaning units to maintain and service components of various vessel systems. Large and small energy producers clean hundreds of large and small parts such as components of hydroand gas-powered turbines that depend on

Fig. 2: Omegasonics will first prove new customer applications in its lab, then provide a video of the procedure.
Ultrasonic cleaning is a fairly straightforward technology, Arata adds, but it is nevertheless vital that the cleaning system satisfy user needs, which should be clearly identified by the sales rep teaming along with the prospective user.

thorough and efficient cleaning to maximize uptime, and each year more gear manufacturers are learning the benefits of this technology as well. Traditionally, parts cleaning has been laborious and costly. The last time we performed an outage on one of our gas turbines, we rented a commercial parts cleaning agitationtype machine, says Kim Townsend, maintenance foreman for power provider Farmington Electric. We would wash the parts for 12 to 14 hours, then take them out and have to hand clean them. I actually had four guys tied up for probably a week of eight-hour days, sitting around the table with little brushes scrubbing and scrubbing and scrubbing. The reason for the extra hand-cleaning was that the rental machine had not done the job. The turbine contains a thousand bolts and several hundred turbine blades, so it was a very time-consuming process. Using the Omegasonics cleaning system, we were able to get all of the parts cleaned up in a matter of four days, he says, and I only devoted one person to it.

QUIcK CONSIdERaTIONS
When proving an application at Omegasonics, Aratas associates ask prospective customers to send sample parts to the test lab so that the best ultrasonic cleaning system may be determined. While one of our models is likely to fit the need, it is important to know how clean the parts should be, Arata explains. That consideration will impact the choice of equipment, the cleaning solution chemistry, and the method of rinsing and drying cleaned parts. Work time is a critical ingredient of the evaluation process. In some instances a part may require immersion in the ultrasonic cleaner for 10 or 15 minutes. This amount of time may impact the choice of a larger unit, or perhaps multiple smaller units that can be

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somewhat unique in designing cleaning systems that facilitate todays cellular manufacturing configurations. Even our large models have wheels, so they may be moved easily if a process changes configuration or if users wish to share equipment between locations. Arata explains that the selection of cleaning solution that is added to the ultrasonic bath water is another variable that is determined by at the test lab. When we are proving a specif-

video. If the customer prefers, the video can be emailed to them for review or further discussion. This is pretty much all the documentation they need to evaluate our recommended solution, Arata says. It also provides another demonstration of how the equipment is truly plug & play. But more importantly, the customer doesnt have to contend with the somewhat esoteric technology of ultrasonic cleaning. They simply push a button to enjoy its benefits. The technical savvy is completely transparent to the customer, because all the necessary hands-on expertise is provided by us. And that usually makes life a lot easier for them.

Fig. 3: Ultrasonic cleaning is a fairly straightforward process, with little training required.
moved to multiple locations if necessary or advantageous. He adds that various models of equipment, ranging from tabletop models to large industrial washers and restoration systems, feature built-in portability. A tabletop model may be very appropriate for smaller applications or those when its advantageous to move the cleaner to the proximity where parts are being serviced, he says. I believe we have been

ic customers application, we make a cleaning solution recommendation. The solution can be supplied directly by us, or in many instances bought sourced from commercial vendors. Once the optimum chemistry is decided the optimum water temperature and ultrasound transducer frequency range is determined. Once these factors are determined, the use of our equipment is literally set it and forget it and requires no other setup than to pull the cleaner out of the box and plug it in. He notes that whenever Omegasonics proves a customer application at the lab, the cleaning process and results are recorded on

about The author:

Ed Sullivan is a technology writer based in Hermosa Beach, California. For more information about Omegasonics contact Frank Pedeflous at (805) 583-0875, frankp@omegasonics.com, or [www.omegasonics.com].

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FOR GEARS
By Nicholas Bugliarello, Biji George, Don Giessel, Dan McCurdy, Ron Perkins, Steve Richardson, and Craig Zimmerman

Different heat treating processesas well as the materials being treatedimpart particular qualities in your gears. Allow Bodycote to provide a deeper understanding of your options.

Heat treatment is a critical and complex element in the manufacturing of gears that greatly impacts how each will perform in transmitting power or carrying motion to other components in an assembly. Heat treatments optimize the performance and extend the life of gears in service by altering their chemical, metallurgical, and physical properties. These properties are determined by considering the gears geometry, power transmission requirements, stresses at different points within a gear under load, load cycling rates, material type, mating part designs, and other operating conditions. Heat treatments improve physical properties such as surface hardness, which imparts wear resistance to prevent tooth and bearing surfaces from simply wearing out. Heat treatments also improve a gears fatigue life by generating subsurface compressive stresses to prevent pitting and deformation from high contact stresses on gear teeth. These same compressive stresses prevent fatigue failures in gear roots from cyclic tooth bending. Physical properties such as surface hardness, core hardness, case depth, ductility, strength, wear resistance and compressive stress profiles can vary greatly depending on the type of heat treatment applied. For any given type of heat treatment the results can be tailored by modifying process parameters such as heating source, temperatures, cycle times, atmospheres, quench media, and tempering cycles to meet specific application requirements. Besides selecting heat treatments that will produce a set

Fig. 1: Typical press quench equipment and tooling design (Source: The Heat Treat Doctor: Fundamentals of Press Quenching by Dan Herring, Industrial Heating April, 1995).
of desired physical properties, manufacturing engineers want to minimize distortion of dimensions from treatment such that final proper fit into a gearbox can be achieved. Many gears are machined into an oversized condition prior to heat treatment so that a planned amount of grind stock may be removed after the process in order to meet dimensional requirements. By selecting heat treatment processes where distortion is reduced, the amount of grind stock needed may be reduced to minimize machining on hardened surfaces after heat treatment and thereby reduce the overall costs of manufacturing. Removing too much of the outermost portion of a case hardened gear that distorted excessively will also negatively impact the fatigue properties and wear life performance. Some heat treatment processes are designed to treat the entire surface of a gear, while others are selective in nature. Induction hardening or selective heating may be employed to harden just the gear teeth only, which can be an effective method of reducing the distortion in a gear. Masking of journals and keyways may be employed in case hardening processes to keep them soft and allow for easier grind stock removal after heat treatment. Reduction of distortion by intelligent heat treatment process design allows manufacturing engineers to improve the performance and/or reduce the overall costs of manufacturing a gear. In all cases, gear design engineers understand that heat treatments play a complex and vital role in both the ease of manufacturing and the performance of the gears they make. Today, many options exist for the heat treatment of gears. Proper selection and design of the heat treatment process can greatly affect performance, ease of manufacture, and economics of a component. This paper will focus on a variety of different processes and highlight some benefits and disadvantages of each.

HEaT TREaTING BaSIcS

To understand heat treating, a basic knowledge of metallurgy is needed. Iron, when combined with small percentages of carbon, forms steel. Plain carbon

Fig. 2: Two fully automated low pressure carburizing furnace lines (Bodycote-Livonia, Michigan).
steels typically contain 1 percent or less carbon in combination with iron. The maximum hardness that any plain carbon steel can achieve during heat treatment is primarily a function of its carbon content. Higher carbon content steels are capable ues than lower carbon content steels. To make alloy steels, small percentages of other elements such as Cr, Ni, Mo, Si, B, V, Ti, Al, N, Nb, W, and Cu (to name the most common) are added to steel. These alloying elements are added in order to increase hardenability or enhance specific properties such as toughness or resistance to softening from heat build-up. For heat treaters the higher hardenability allows for slower quenching, which means distortion can be kept to lower levels in more highly alloyed steels. Steels can

Fig. 3: Hardness and compressive stress proles generated by LPC of being hardened to higher hardness val- (compare to g. 4).

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Fig. 4: Hardness and compressive stress profiles generated by atmosphere carburizing (compare to fig. 3).
After quenching to the maximum hardness achievable, which is determined by the steels carbon content, the steel may then be tempered down to a lower hardness to improve ductility and toughness at the expense of slightly reducing the strength, hardness, and wear characteristics of the material. What actually occurs in steel during heat treating are phase transformations as atoms rearrange themselves into different crystal structures. The starting point of most heat treated parts is an be annealed by thermally processing at a high temperature and slow cooling to soften it. In this soft and malleable state it can be machined, formed, hobbed, and ground easily into a desired shape. What makes steel industrially important is that it can be hardened after the material has been formed or shaped in the soft state to a desired geometry. By use of a thermal processing cycle where steel is heated to austenitizing temperatures and rapidly quenched, the near-finished components can be hardened to improve wear resistance, strength, and hardness. annealed material. In fact, when purchasing steel it is generally in the annealed condition. An annealed structure is a combination of primarily ferrite (Fe, pure iron) and iron carbide (Fe 3 C, cementite). These will be in the form of alternating layers of ferrite and Fe3C (pearlitic structure), or ferrite

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with dispersed Fe3C spheres or spheroids (spherodized structure). When steel is heated above its austenitizing temperature, it transforms into the austenite structure. An approximate austenitizing temperature for most plain carbon steels is around 1330F and varies by exact grade of steel. Once full transformation of the steel to an austenite structure has occurred the austenite may be quenched (cooled rapidly), and that austentite structure will transform to a martensite structure. This transformation of austenite to martensite

is the hardening process. The martensite structure yields the highest hardness and tensile strength properties of any structure for that steel. Producing a martensitic structure from austenite is the goal in hardening heat treatment of steels. One critical aspect of this hardening process is the cooling rate employed during quenching. Each grade of steel requires that a certain minimum cooling rate be achieved during quenching or the transformation from austenite to martensite will not occur. Austenitized steels held at high tempera-

Heat Treatment Method

Relative Load Distortion Carrying Capability 1=low, 1=high, 5=high 5=low 4 2 2 3 2 4 4 4 2 2 2 2 2 1 2 5 5 5 2 2 3 4 4 2 4 5

Wear Fatigue Quality Capital Relative Resistance Resistance Risk Cost Piece Cost 1=high, 1=high, 1=low, 1=low, 1=low, 5=low 5=low 5=high 5=high 5=high 5 5 5 2 2 2 2 2 2 2 2 3 3 2 5 5 5 5 5 5 5 4 4 4 2 2 2 2 2 1 1 3 4 4 2 4 3 3 3 2 4 5 1 1 2 3 3 3 3 4 2 2 3 3 3 4 3 3 3 3 5 5 5 2 2 3 3 3 3 3 4 5 5 3 3 3 2 3 3 3 4 3 1 1 3 3 5 4 4 4 4 5 5 5 5 2 2 5 4 4 4 4 5 1 4

Atmos Neutral Harden & Oil Q Atmos Neutral Harden & Hot Oil or Salt Q Atmos Neutral Harden & Press Q Atmos Carburize & Direct Oil Q Atmos Carburize & Direct Hot Oil or Salt Q

Atmos Carburize, Cool, Reheat, & Oil Q 3 Atmos Carburize, Cool, Reheat, & Hot Oil or Salt Q 2 Atmos Carburize, Cool, Reheat, & Press Q 2 Low Pressure Carburize & Direct Oil Q Low Pressure Carburize & Direct Gas Q Nitride Ferritic Nitrocarburize Ferritic Nitrocarburize & Oil Q Carburize, Cool, & Induction Harden & Q Induction harden (single shot low frequency) & Q Induction harden (single shot mid frequency) & Q Induction harden (single shot high frequency) & Q Induction harden (single shot dual frequency) & Q Induction harden (tooth by tooth) & Q Flame harden (spin) & Q Flame harden (tooth by tooth) & Q 2 1 1 1 1 2 2 2 1 1 1 5 1

Table 1: Common heat-treating methods for gears. 42 gearsolutions.com

ture and quenched too slowly down to ambient temperature will not transform from austenite to a martensitic structure. They will instead revert back a softer mix of ferrite and cementite again. Table 1 summarizes the methods in common use today for heat treatment of gears. Each method has its place; some are perfect for high volumes, while others are practical only on a piece-by-piece basis. Some improve all metallurgical properties, while others improve only one or two.

NEUTRal HaRdENING
There are two general classifications of heat treatments used for hardening steels: neutral hardening, and case hardening. Neutral hardening refers to maintaining the carbon potential of the atmosphere at the same percentage as the carbon in the steel during the hardening cycle. This means that carbon is entering and leaving the surface of the steel at the same rate, and no net gain or net loss of carbon atoms inside the surface of the steel occurs. Many gears are neutral hardened, but for the most demanding applications case hardening processes, such as carburizing and nitriding, are the preferred methods due to their improved wear characteristics and mechanical properties.

ATmOSpHERE CaRBURIZING
Carburizing, the most widely used form of surface hardening, is the process of diffusing carbon into the surface of low carbon steel at elevated temperatures. This results in a high carbon case forming just inside the surface of a low carbon component. During quenching from austenitizing temperatures the austenite will transform to martensite, and the higher carbon case will have a high hardness while the lower carbon core material will have a lower hardness. The goal of this process is to produce a hard, strong, wear resistant outer surface while retaining a softer, ductile tough core. When austenite transforms to martensite during quenching, a volume expansion occurs in the material and it grows. The volumetric expansion in the case is greater than the volume expansion in the lower carbon, lower hardness core structure. This difference in size changes puts the carburized surface of the part into a state of compression, which makes it stronger. For example, when a force is applied to a gear tooth, it first has to overcome these compressive forces before beginning to put the surface of the tooth in tension. In order to deform this material, it requires a force that exceeds the combination of overcoming the compressive stresses present in addition to the normal yield strength of the material. These compressive stresses caused by differences in volume expansion rates between the case and core improves the overall tensile and yield strength of the carburized case inside a gear tooth. It is these compressive stresses that resist deformation from high contact stresses present as gear teeth press and roll against each other. These compressive stresses also increase fatigue life by helping to prevent cracking

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Fig. 5: LPC process: carburized case in gear root (left), carburized case in gear tooth (right).
in tooth roots as the teeth are cyclically loaded and unloaded with bending stresses. The high carbon, high hardness surface of the carburized case also resists wear and scoring caused by friction as gear teeth rub and wear against each other. One cant discuss heat treating gears without discussing distortion, which occurs for a variety of reasons. One source is pre-existing residual stresses present in the material caused by prior operations such as steelmaking, rolling, forming, forging, casting, machining, and grinding. As the material begins to heat up during carburizing, these residual stresses present in the material relieve and cause the gears to distort if these stresses were large or non-uniform.

Fig. 6: No presence of intergranular oxidation after LPC process.

A second source of distortion is high temperature creep during processing. Gravity is the enemy of many gear designs during thermal processing, especially in carburising, where high temperatures and long processing times are the norm. At high temperatures, steel has little strength and can sag and bend under gravitys force if sections of a part are not properly supported or components not stood up or hung perfectly straight. Spending the extra time to fixture parts correctly and designing customized fixtures to properly support a gear during exposure to high temperatures can save many hours of straightening and machining afterwards. Some part shapes such as long shafts are best racked in vertical orientations to maintain straightness

Heat Treating Services:

Carburizing, Carbonitriding, Hardening Marquenching for Distortion Control Nitriding/Ferritic Nitrocarburizing Induction Hardening Gleason Press Quenching Flame Hardening
ISO/TS 16949:2009

Other Services Include:

Aluminum Processing Neutral Salt Bath Hardening Stress Relieving Tool Steel Processing High Temperature Alloy Age Hardening Long Parts Stainless Steel Processing Sub-zero Treating Metallurgical Consulting Annealing & Normalizing ADDITIONAL MANUFACTURING SERVICES AVAILABLE
ISO 14001:2004

5701 Mariemont Avenue Cincinnati OH 45227

Phone (513) 271-3173 Fax (513) 271-3510 www.steeltreating.com

CQI 9 Compliant

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Booth# N6414

while other shapes such as rings are better if laid flat horizontally to maintain roundness. Selection and experience in designing heat treatment fixtures can dramatically affect the results. A third source of distortion is quenching, which is typically the main offender in distorting parts during heat treatment. The ideal quench is the slowest quench that will uniformly pull heat out of the part, while still fully transforming the surface to martensite and achieving the desired case and core properties. This sounds easy enough, but in practice it can be quite difficult given the design and complex shape of many gears. Due to variations in customers part geometries, limitations in fixture designs, non-uniform quench tank agitation, and part-to-part or part-to-fixture interactions, it is the most difficult distortion mechanism to resolve and predict. Even within a single part its possible to have some thinner sections of a component cool faster than thicker sections causing one area to transform

Fig. 7: Dual frequency induction patter (left), single frequency induction patter (right).

Fig. 8: Single tooth hardening.

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earlier than another and warp dimensions as the transformations with their associated volume expansions occur at different times during a quench. When distortion occurs to an unacceptable degree, solutions need to be found. After exhausting all the variations of processing parameters, fixturing methods, quench modifications, and ensuring parts are free from stress prior to heat treatment, other options need to be considered. This can be as simple as a straightening step, or as difficult as re-engineering the part. Some other methods of heat treating may provide more effective solutions to reducing distortion as well. Processes such as press quenching, tooth to tooth induction hardening, vacuum carburizing with gas quenching, and nitriding are employed when excessive distortion results during conventional carburizing of specific gear geometries.

when the heat treater is trying to expand the tooling out to meet an intended bore diameter prior to the actually quenching the part. The intent is to minimize any out of round conditions that may occur. Larger bore diameter gears with thin wall thicknesses are prime candidates for the use of an expander to prevent any out of round conditions. A plug is used for holding a bore dimension. The plug is ground to a size close to the intended bore diameter. The heat treater is trying to have the bore cool or shrink uniformly to a certain dimension. A finish grinding operation of the bore is usually performed after plug quenching. The focus on gear press quenching should not be on the use of tooling. It has been taught that the best gear starts with the gear blank. Addressing the forging operation for the gear blank is important. In the forging operation, the direction of the grain pattern is critical such that the part will not have non-uniform residual stresses present. It is important that the blank also be normalized or annealed at temperatures that exceed the planned carburizing temperature by 50 degrees F. It is also important to ensure that the cycle time at temperature is held for a proper length of time. Insufficient time or temperature during normalizing or annealing will result in greater distortion being present during subsequent heat treatment steps. It is often recommended to perform a subcritical stress relieving operation after the rough machining of the gear blank to help minimize distortion in the final heat treating operation. While not considered absolutely necessary, it does help reduce distortion and improve the final quality of the part. Another concern that comes up in gear hardening is the tapering of the bore diameter through the length of the bore. This arises due the sectional changes present in some gears along their axis. The use of an expander and using various pressures on the inner cylinder will result in minimizing tapering. Tapering cannot be eliminated in some gear designs, but it can be minimized. When designing gears where press quenching is planned, it is recommended to have the heat treater involved from the design stage to understand how it will affect the final product. Press quenching is not the lowest-cost hardening process available, but it is a competitive process among todays gear hardening processes. In many cases press quenching is the only option, as distortion from conventional carburizing and quenching processes can be too excessive on some sensitive gear geometries.

PRESS QUENcHING Of GEaRS

The art of press quenching while being around for decades remains somewhat of a mystery to the engineering world, and even our own heat treating industry. In basic form, gears are carburized in large batches, slow cooled, reheated individually, and then quenched rapidly under some form of restraint to minimize distortion. The main dimensions that are restrained during press quenching are the flatness of the gear and the roundness of the bore in relation to the hub. The quenching equipment utilized is referred to as a press. They are either pneumatic or hydraulic in design, depending on the individual piece of equipment. The press has a lower die assembly that floats in nature and becomes stationary during the quench process. The upper die uses a primary and secondary upper pressure system that has two levels of controls through an outer and inner cylinder assembly. Depending on the press being used the maximum die pressure is different. When the gear is transferred to the press and placed on the die for quenching, it is restrained through the use of tooling designed specially for the gear being quenched. Oil flow becomes critical to the success of the pressing operation to minimize any distortion. The oil flow comes up from the oil reservoir through the chambers or holes within the lower die assembly, then circulating up and around the table to the oil flow rings based on the lower die table. The oil flow can be controlled through the manipulation of oil flow rings, which are located underneath the support rings. The oil flow can be restricted or wide open depending on the gear being quenched. This flow is regulated through timer controlled valves. The inner cylinder force is exerted against the rim of the gear to address flatness while the outer cylinder can be used to apply pressure to the face of the hub or to apply pressure to expand out an expander mandrel in the attempt to control the spline or bore sizing. Whether a plug or an expander is used in a bore depends upon what is trying to be accomplished. An expander is employed

LCP/HIGH PRESSURE GaS QUENcH

Low Pressure Carburizing (LPC) with high pressure gas quench is a relatively new carburizing technology that has become more widely used during the last decade. It has become the popular choice of carburizing treatment for automotive transmission gears over the last 10 years with General Motors, Ford, Chrysler, and many foreign automakers now adopting this process. Many fuel injectors are currently carburized using this technology. Some aerospace components are also being low pressure carburized,

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with rotorcraft transmission gearing being another early adopter of LPC. LPC equipment comes in a variety of forms from different furnace manufacturers that all have different concepts and designs. In general, the equipment consists of vacuum chambers capable of heating parts to carburizing temperatures and capable of injecting small amounts of hydrocarbon gases at low pressure that act as a carbon source. In addition to the carburizing cells there are quenching cells where carburized hot loads may be cooled using high pressures of inert gases to rapidly cool the parts allowing hardening to occur by transforming austenite to martensite in the case and core structure. The gas quench cells are equipped with powerful fans and are capable of injecting gases typically up to 20 bar positive pressure in conjunction with heat-exchangers using chilled water to quickly remove heat from the quenching gases. The most common quenching media is high pressure nitrogen gas, and the more common carburizing gases are propane and acetylene. Many furnace manufacturers are using different gases, however, and blends of gases as carbon sources and quench gases. High hardenability alloys are required for LPC and high pressure gas quench. Typical grades of materials used are 8620, 5120, 4118, 17CrNiMo6, 9310, 3310, 8822H, 4822, and 8630. Lower hardenability plain carbon steels that can be carburized and oil quenched simply cannot be hardened using a gas quench because they will not properly transform as cooling rates are too slow. Even with high hardenability grades some consideration must be given to core hardness, as the gas quench will produce lower core hardness compared to oil quenched parts. A major advantage of LPC is that these same slow cooling rates during gas quenching translate into low distortion from quenching. Many parts that cannot be successfully oil quenched and maintain required dimensional tolerances are able to be LPC processed with a gas quench and yield acceptable dimensions. By eliminating the non-uniform cooling of parts associated with liquid quenches that have vapor, boiling, and convective cooling all taking place simultaneously and replacing it with gas quenches that have slower cooling rates and are more uniform and purely convective, distortion can be greatly reduced as gear surfaces are more uniformly cooled at slower rates. LPC with gas quenching can sometimes eliminate post-heat treatment straightening or clamp tempering operations, reduce grind stock allowances and hard machining, or replace more costly processes such as press quenching of individual gears. A second advantage of LPC is cleanliness of the parts after processing. The finished parts emerge from the furnace very clean. At times it is almost difficult to identify the heat-treated and non heat-treated parts. For this reason the heat-treated parts are slightly discolored, using the discoloration process to identify the heat-treated parts. In comparison, conventional carburizing uses oil quenching where the oil will burn onto the surfaces and

finished parts are often dark, sooty, and have oil residue left on the surfaces. Another advantage of the LPC process is that it has the capability to utilize a higher carbon potential atmosphere during the boost thus obtaining higher hardness values deeper into the case in comparison to the conventional carburizing. This higher hardness deeper into the surface before transitioning to the core imparts greater compressive stresses to the surface case material and improves the fatigue properties and resistance to deformation by high single point rolling contact stresses on gear teeth. Another advantage of LPC processing over conventional carburizing is the depth of case attainable in gear tooth roots. The pitch to root ratio of the effective case depth after LPC is remarkably uniform. Oftentimes in conventional carburizing of gears, the case depth in the roots of teeth may only amount to half the case depth present at the mid-pitch tooth location. With LPC processing, the effective case depth present in the gear roots is nearly equivalent to the case depth present at the gear tooth midpitch location. This deeper case depth present in the gear tooth roots enhances fatigue life under tooth bending conditions and will outperform conventional carburized parts in this aspect. Another advantage of LPC is the absence of any inter-granular oxidation (IGO) on the surface of the part. This saves the gear manufacturer from grinding off the case to remove the IGO and saves valuable time and manufacturing costs. Typically .0003 to .0007 deep IGO will be present on any gears carburized in conventional endothermic atmosphere furnaces. The LPC process produces excellent metallurgical and dimensional results which are required for high performance transmission gears. There are many types of gears and products well-suited for the LPC process and the advantages of this process have been outlined above. The main disadvantages of this process are that LPC equipment is capital intensive and the consumables are expensive. Process engineering, operation, and maintenance require higher skill levels than traditional carburizing. There is also a limitation of load sizes that can be processed as the gas quenching requires that lighter loads be processed in order to cool them rapidly enough.

GaS NITRIdING
The gas nitriding process for case hardening of alloy steels allows complex configurations to be treated with minimal distortion. This process is performed at low subcritical temperatures and completely avoids the problems of structural transformations associated with high temperature austenitizing and quenching of steel during carburizing. Earlier in this article we detailed the three causes for distortion in carburizing which included stress relieving of pre-existing residual stresses, high temperature creep distortion, and phase transformations upon quenching. Since there are no phase transformations at low nitriding tempera-

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tures, there is no distortion from phase changes. There is little concern for distortion due to high temperature creep at the low subcritical nitriding temperatures. That leaves only stress relief of residual stresses as a possible cause of distortion during nitriding. In order to eliminate this source of distortion a typical manufacturing sequence for nitrided gears would be to rough machine, stress relieve at 50 degrees F above the nitriding temperature, final machine putting as little stress into the parts as possible, and then nitride. Nitriding is often performed on finish-machined components with little distortion and usually requires no postheat treatment machining to clean up the tolerances. The nitriding process basically consists of placing steel surfaces at nitriding temperatures in contact with ammonia gas (NH3). The ammonia dissociates at the steel surface providing atomic nitrogen which can then diffuse into the gear, react with specific alloying elements in the steel, and form alloy nitrides which creates a hardened wear resistant case below the gears surface. There are many benefits of the gas nitriding process. Its purpose is to produce a very hard, wear resistant, load bearing case in relatively inexpensive alloy steels. The low treatment temperatures keep distortion and growth to a minimum and it is typically performed on finish-machined parts. This process is very simple to run and has fewer variables to control than the other case hardening processes discussed earlier. The lack of quenching which is a major source of variation in carburizing results is not present

in nitriding and allows for better control and greater repeatability. The nitrided case also is not softened or tempered like carburized gears, which start to lose hardness at temperatures as low as 300 degrees F. Nitrided cases will not soften until exposed to temperatures above 1000 degrees F and can withstand high service temperatures. Isolated surfaces can be masked from nitriding and left soft for ease of machining, welding, or other purposes. The corrosion resistance of some low alloy steels is also slightly improved by nitriding. Some limitations of gas nitriding include only being able to achieve shallow case depths (0.030 max for some materials) due to the low diffusion temperatures. The nitriding alloy selections are limited to materials that contain Cr, Mo, V, Ti, W, and Al alone or in combination. There are occasional problems with spalling of the case if nitriding networks form, but this can be minimized with proper controls. Nitrided stainless steels lose much of their corrosion resistance by nitriding as chromium becomes bonded to nitrogen, which breaks down the protective chromium oxide layer normally present on stainless surfaces. The gas nitriding process is a readily available heat treatment process that creates an extremely hard, load bearing wear resistant surface with depths ranging from .005 to .025 depth. It can be performed on many commonly available alloy steels with minimal size change and high retention of core mechanical properties.

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INdUcTION HaRdENING GEaR TEETH

Induction heat treating is localized heat treatment used to increase the fatigue life, strength, and wear resistance of a component. Induction hardening is accomplished by placing the part inside an alternating magnetic field causing an electrical current to form at the surface. Heat is generated as a result of the I 2R losses in the material and allows heat treaters to selectively austenitize only the surface material of a component while leaving the core material untransformed. Not only is the surface only selectively heated, but induction allows only those desired surfaces to be heated while other surfaces may be left cold. In the case of gears it is possible to only austenitize the near surface of a single tooth leaving the balance of the part cold during processing. The heated gear surface is subsequently quenched in either water, oil, or a polymer based quench to transform the

austenite into martensite thereby increasing hardness in the required area while leaving the remainder of the component virtually undisturbed. Gear Hardening: There are numerous factors that determine the appropriate induction hardening process to choose. Items such as geometry, permeability of the material, and desired mechanical properties will dictate processing variables such as frequency, power density, and heat time. There are many frequency selections to choose from when hardening gears. The relationship between frequency and current penetration depth are inversely proportional. Such that lower frequencies cause the current to form at deeper depths while higher frequencies generate heat immediately adjacent to the surface. Tooth form is a significant factor when selecting the correct frequency, as high frequencies will heat the tooth tips first and low frequencies will heat the roots first.

Power density and heat time are crucial to achieving the desired mechanical properties with the least amount of dimensional movement and associated risk of cracking. When calculating power densities a target value of 12 KW/in2 should be used to minimize total heat penetration into the component core. Heat time should always be optimized to achieve full transformation to austenite at the desired hardening depth. Profile Induction Hardening: Profile induction hardening produces a tough core with associated tensile stresses and a hardened surface layer that exhibits compressive stress in the tips, flanks, and roots. Extensive product validation testing has determined that this combination of stresses best extend the components fatigue life and wear resistance over other types of induction hardening while also producing the least amount of dimensional movement. The most common method of obtaining a profile hardening pattern is to use a

 Gears complete to print up to 16 inches in diameter offering AGMA class 12 quality  Gear grinding services up to 27.8 inches in diameter featuring newer CNCgear grinders Quantities of 1 to 100 pcs. Analytical Gear Charts to insure quality

4884 Stenstrom Road Rockford, IL 61109 Phone: 815-874-3948 Fax: 815-874-3817

w w w . r a y c a r g e a r . c o m

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blend of frequencies to actually heat the tips, flanks, and roots concurrently. This is accomplished by simultaneously generating high and low frequencies and passing them through the inductor at the same time. This type of power supply is relatively new to the market and is referred to as a simultaneous dual frequency generator. Most of these units allow the technician to individually adjust the intensity of the various frequencies seen by the part. This provides them the flexibility to customize or sculpt the shape of the pattern to the specific geometry of the tooth. Single Tooth Hardening: Single tooth hardening is primarily used to induction heat treat gear teeth to improve strength and wear characteristics. The process is accomplished by hardening one tooth root at a time. After each root has been hardened the system indexes the part to the next position and the process begins again. This process is time consuming as a 55 tooth gear will take 55 hardening cycles to complete. However, it is primar-

ily used to harden very large, low volume parts that could not be done using conventional equipment due to the massive power requirements associated with heating the entire part at the same time or very large diameter gears that will not fit inside any existing carburizing furnaces. To harden a tooth root the coil rests in between to adjacent teeth. This configuration hardens the tooth root and the flank of each adjacent tooth as shown in fig. 8. This method of hardening provides strength and wear resistance on the contact areas of the gear while minimizing dimensional movement by leaving the tooth tips unhardened.

factor in heat treatment processes, but it can be controlled and minimized by selecting specific processing parameters, being knowledgeable about fixturing, using different types of case hardening processes, and taking extra steps to ensure the gears have minimal stresses present in them prior to heat treatment that could be relieved. No one heat treat process is superior to the other, but ultimately they all compliment each other. Having an understanding of the processes available will help you choose which process is appropriate for your gear.

about The authors:

Nicholas Bugliarello, Biji George, Don Giessel, Dan McCurdy, Ron Perkins, Steve Richardson, and Craig Zimmerman are with Bodycote. To learn more contact Zimmerman, director of technology development, at craig.zimmerman@bodycote.com. Also go to [www.bodycote.com].

CONclUSION
A variety of heat treatment techniques exist for case hardening gears. Heat treatment processes can be tailored to maximize the life and optimize the performance of a gear in its service application by tailoring the heat treatment to produce specific desired properties. Distortion is always a

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Booth# W1492

880 N. Washington Ave. Kankakee, IL 60901 Toll Free: 1.800.786.7562 Fax: 1.800.315.8769 email: sales@storloc.com

STOR-LOC MODULAR DRAWER SYSTEM

www.storloc.com

PRoDUCt
SHOWCASE
New products, equipment, and resources

NTG Tool and Cutter Grinder from Star Cutter

Armed with NUMROTOplus software, the NTG tool and cutter grinder from Star Cutter is designed for manufacturing and reconditioning end mills, drills, step drills, taps, and form cutters quickly and precisely. NTGs three-station wheel and manifold changer switches grinding wheels in 10-15 seconds. The high volume auto load/unload system holds up to 288 parts and loads and unloads tools half an inch in diameter by up to eight inches long to an automated tailstock center in 15 seconds or less. Linear motors on two horizontal axes eliminate the need for ball screws and reduce the number of moving parts, lowering maintenance costs, and improving surface finishes. And since the loader is integrated in the standard enclosure, the NTG takes up 30 percent less floor space than earlier generation machines. See the NTG at IMTS 2010 booth #N-6924. Also call (847) 649-1450, e-mail sales@star-su. com, or visit [www.starcutter.com].

General Purpose, High Performance Tap from Emuge

Emuge Corp. introduces the MultiTAP, the industrys first high performance tap designed to cut a wide range of materials including carbon steel, steel alloys, stainless steel, aluminum, cast iron, copper, brass, and bronze. MultiTAP is also uniquely designed to produce threads within both 2B and 3B classes of fit, eliminating the guesswork of calculating H-limits. Emuge is widely known for manufacturing high performance application-specific taps, thread mills, and end mills for high production output, but the MultiTAP offers job shops and other manufacturers an affordable, high performance tapping solution for a wide variety of common materials and applications. MultiTAP is the ideal tap for a job shop or a manufacturer who works with short and medium run threading applications across a wide spectrum of materials, says Peter Matysiak, president. It will significantly improve thread quality and boost output while reducing production costs. Visit www.emuge.com.

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Bevel Gear Grinding Wheels from Gleason

Gleason Corporation has broadened its line of bevel gear manufacturing solutions with a new line of high performance grinding wheels for bevel gear applications. The new wheels have been developed to Gleason standards, using the latest, most advanced abrasive materials and wheel designs, enabling faster, more aggressive metal removal rates. With the new high-performance series of wheels, bevel gear grinding from a solid gear blank becomes an economically viable alternative to the traditional process of rough cutting prior to grinding, with significant reductions in equipment and tool costs, setup times, and cycle times. Beyond grind from solid applications, the series covers virtually any bevel gear or Curvic Coupling application, from very small to large diameters, industrial to aircraft precision, low to very aggressive metal removal rates, and all ranges of steels and very hard materials. Visit online at [www.gleason.com].

New High-Feed Cutter from Ingersoll

The new Power-Feed+Mini high feed cutter from Ingersoll Cutting Tools features high-speed geometry with a double-sided, four-edge insert. This innovative insert was engineered specifically for highspeed machining to deliver economy, strength, and performance. The robust insert has an exceptionally strong cutting edge. The infusion of proven PowerFeed+ technology into a smaller insert provides high-feed capabilities with higher insert densities in smaller diameter end mills. The cutter bodies incorporate features such as through coolant and are constructed of premium alloy steel materials. When high speed roughing at lighter depths of cut is the challenge, the Power-Feed+Mini is the answer. For more information call (815) 387-6600 or visit [www.ingersoll-imc.com].

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FANUC to Unveil CNC Innovations at IMTS

FANUC CNC America will display advanced CNC control innovations at IMTS 2010 booth #S-8919. The 30i-B Series Control is an upgrade from the 30i-A Series, offering newly enhanced features and functions with advancements in operability and maintainability. The 0i-D/0i-D Mate Control offers newly enhanced features and functionality that are powerful, yet cost effective. The new 35i-B Control, based on the cutting-edge 30i-B series, is for transferline machines and ideal for simple high speed drilling and transfer machining. The companys new five-axis volumetric error compensation increases machining accuracy by evaluating the tool location and orientation error throughout the machining volume. This offers significant improvements over axis-only error compensation. Call (888) FANUC US (or 326-8287) e-mail fanuc. marketing@fanuccncamerica.com, or visit www.fanuccnc.com.

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High Precision Tooling Adapters from EXSYS

EXSYS Tool, Inc., will be showcasing a variety of its high precision tooling adapters at IMTS booth #W-1474. The companys PRECI-FLEX is the first tooling system on the market with a single base holder and multiple tooling adapters that utilizes the ER collet pocket, making lathe tooling changeovers quick, accurate, and cost effective. The products compact design ensures maximum torque transmission and rigidity, resulting in increased machining accuracy and improved productivity. Additionally, the modular systems conical and flat face planar interface allows the use of either an adapter or a standard ER collet, and enables collets, endmill holders, expanding collet chucks and shrinks fit tooling to be mounted on a single base holder. For more information contact Stewart Bachmann at sbachmann@ exsys-tool.com. Also visit [www.exsys-tool.com].

Multifunction Gear Shaving Machine from SICMAT

Designed for finishing high quality gears for various markets, the Raso 200 CNC shaving machine from SICMAT shaves gears with diameters ranging from 6 to 200 mm and module from 0,8 to 5 mm. Thanks to its lathe-like structure, the Raso 200 provides performance levels and stiffness comparable to larger machines in a much smaller space. The Raso 200 is equipped with PILPRO (Piloted Programming) software that is Windows-based and user friendly, allowing operators to quickly and safely program complex shaving cycles. In addition to traditional cycles, mixed cycles (plunge plus diagonal), progressive diagonal cycles or combined double cycles can be programmed. See the RASO 200 gear shaving machine at IMTS in Star SUs IMTS booth #N-6924. Also call (847) 649-1450 or visit [www.star-su.com].
Continued on page 62 >

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featuredSuppliers
Midwest Gear Corporation REF #101 Phone: 330-425-4419 Fax: 330-425-8600 Email: sales@mwgear.com Website: www.mwgear.com New England Gear REF #102 Phone: 860-223-7778 Fax #:860-223-7776 Email: jeff@newenglandgear.com Website: www.newenglandgear.com R. P. Machine Enterprises, Inc. REF #103 Phone: 704-872-8888 Fax #:704-872-5777 Email: sales@rpmachine.com Website: www.rpmachine.com Repair Parts, Inc. REF #104 Phone: 815-968-4499 Fax #:815-968-4694 Email: rpi@repair-parts-inc.com Website: www.repair-parts-inc.com Havlik International Machinery, Inc. REF #105 Phone: 519-624-2100 Fax: 519-624-6994 Email: havlik@bellnet.ca Website: www.havlikinternational.com GQ Machinery Inc. REF #106 Phone: 516.867.4040 Fax: 516.223.1195 Email: george@gqmachinery.com Website: www.gqmachinery.com

MACHINERY
Contact Gear Solutions at 800-366-2185 to list your machinery.
BARBER-COLMAN #16-36, 24 Dia, C-Frame Style, 4 1/8 Bore REF#103 BARBER-COLMAN #16-56, 16 Dia, 56 Face, Differential REF#103 BARBER-COLMAN #22-15, 22 Dia, 14 Face, Differential REF#103 DAVID BROWN, 138 Dia, Face 60REF#103 G&E #24H Universal Head, Infeed, Tailstock, Differential, 50s REF#103 HAMAI #120, 4.8 Dia, 4 Face, 12 DP, 70 REF#103 LIEBHERR #L-402, 16 Cap, 2-Cut Cycle, Crowning, 77 REF#103 LIEBHERR #L-650, 26" Dia Cap, 14.5" Face, 2.5 DP, New 70s REF#103 MODUL #ZFZW 800, 29.8 Dia, 16.25 Face, 2.5 DP Crowing, 2-Cut REF#103 BARBER-COLMAN #1600-36, 16" Dia., 39.5" Face, 6 DP REF#103 CHONG QIN #Y3180H, 31.5 Dia., 15" Face, 3 DP REF#103 FELLOWS FH-200 Max Diam 7.87" Max Dia Pitch 5.08" REF#103 G&E #16H Gear Hobber, 16"Dia REF#103 BARBER-COLMAN #3 (6-10), Single & Triple Tread Worm HS REF#103 BARBER-COLMAN #6-10, 6 Dia, 10 Face, 16 DP REF#103 KOEPFER #140 , 2.75 DIa, 4 Face REF#103 KOEPFER #153B, 5.6 Dia, 5.9 Face REF#103 LANSING #GH-50, 50 Dia, 17.75 Face, 2 DP REF#103 LIEBHERR #L-252, 9.8 Dia, 7.9 Face, 4.2 DP REF#103 MIKRON #79 1.5 Dia, 26 DP REF#103 BARBER-COLMAN TYPE T REF#103 IUG Craiova FD-3600 REF#103 LIEBHERR #L-401, 15.7 Dia 11 Face, 3DP REF#103 G&E #36HS 36Dia, 14 Face 3 DP REF#103 PFAUTER #P-3000, 120 Dia, Single Index REF#103 SCHIESS RFW-10-S 55 Dia REF#103 SHIBURA HHC-250A Single Index REF#103 OVERTON #HD-400, 15.7 Dia, 12 Face, 3 DP, New 88 REF#103 SCHIESS 1 RF-10, Dia 60 150 L, .50 DP REF#103 G&E #40TWG, 48 Dia, 18 Face, 3 DP REF#103 G&E #60S, 72 Dia, 14 Face, 1.25 DP REF#103 G&E #72H, 72 Dia, 24 Face, 1 DP REF#103 G&E #96H, 104 Dia, .50 Face, 1.25 DP REF#103 PFAUTER #P-630, 25 Dia REF#103 PFAUTER #2500, 100 Dia REF#103 TOS FO-16, Max Cut w/support 90 REF#103 PFAUTER P250 10 Dia REF#103 GE Hobber 200 Dia, 55 Face REF#103 GE/Fitchburg Hobber 32 Dia, 72 Face 1.25DP REF#103 JF Reinecker 40 Dia 35 Face REF#103 LIEBHERR L-160-R 6.5 Dia REF#103 MIKRON #102.04 , 4 Dia, 5 Face REF#103 NIHON-Kikai NDH-1200 50 Dia REF#103 PFAUTER P-900 36 Dia REF#103 SCHIESS RF 40/60S 240 Dia 100 Face REF#103 BARBER-COLMAN #25-15 25 Dia, 15 Face, 2.5 DP REF#103 CRAVEN Horizontal , 18 Dia and 100 Length REF#103 KOEPFER #173B, .6.1 Dia, 7 Face REF#103 PFAUTER #P-630R, 25" Max. Spur Dia, 12" Max Rotor Dia. 12" REF#103 BARBER-COLMAN 2 1/2 -4, S/N 119, 62 Hi-Production Spur Gear REF#104 BARBER-COLMAN 6-10 SYKES, Triple Thrd w/Lever Operated Collet Assy REF#104 BARBER-COLMAN 6-10 B&C Ltd, S/N 8079, Triple Thrd REF#104 BARBER-COLMAN 6-10, S/N 4626, 57 Triple Thrd 3 Hob Slide REF#104 BARBER-COLMAN 6-10, S/N 4659R, 56 Triple Thrd Adj Ctr Assy REF#104 BARBER-COLMAN 6-10, S/N 4665, 57 Fine Pitch Prec Triple Thrd REF#104 BARBER-COLMAN 6-10, S/N 4701, 58 Triple Thrd w/Power Down Feed REF#104 BARBER-COLMAN 6-10 M/C, S/N 4755, 59 Triple Thrd w/MC Conversion REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 4778R87, 60 (87 Rebuild), Sgl Thrd Hi-Spd REF#104 BARBER-COLMAN 6-10 M/C, S/N 4913, 63 Triple Thrd w/90 Deg Hob Slide REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 5055, 66 Triple Thrd, 800 RPM REF#104 BARBER-COLMAN 6-10, S/N 5141, 67 Triple Thrd w/Prec Hob Shift REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 5148, 68 Triple Thrd, 800 RPM REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 5259, 75 Triple Thrd w/Auto Hob Shift REF#104 BARBER-COLMAN 6-10, S/N 5353, 77 Triple Thrd w/3 Hob Slide, 800 RPM REF#104 BARBER-COLMAN 6-10, S/N 5394, 81 Fine Pitch Triple Thrd w/Dwell & Hob Rev REF#104 BARBER-COLMAN 6-16 M/C, S/N 5238, 70 Triple Thrd, Recon 02 REF#104 BARBER-COLMAN 6-10, S/N 5407, 82 Auto w/PLC Control REF#104 BARBER-COLMAN DHM, S/N 105, 42 Double Thrd REF#104 BARBER-COLMAN 14-15, S/N 635R, 53 Dbl Thrd, Fact Reb REF#104 BARBER-COLMAN 14-15, S/N 745, 55 Dbl Thrd w/Dwell REF#104 BARBER-COLMAN 14-15 Dual Fd, S/N 938, 62 Dbl Thrd, Comp Reco REF#104 BARBER-COLMAN 14-15, S/N 1055, 65 Dbl Thrd w/New Hyd Sys REF#104 BARBER-COLMAN 14-15, S/N 1131, 66 Dbl Thrd w/Hyd Tailctr REF#104 BARBER-COLMAN 14-15 Dual Fd, S/N 1261, 67 Dbl Thrd w/Hyd Live Ctr REF#104 BARBER-COLMAN 14-15 Dbl Cut, S/N 1278, 68 Dbl Thrd w/4-1/8 Bore REF#104 BARBER-COLMAN 14-30 Dual Fd, S/N 1371, 71 4-Thrd w/Sizing Cycle REF#104 BARBER-COLMAN 22-15, S/N 923, 62 Dbl Thrd, Dbl Cut REF#104 BARBER-COLMAN 16-11, S/N 184, 50 Dbl Thrd w/Vert DRO REF#104 BARBER-COLMAN AHM, S/N 1896, 42 Sgl Thrd w/3 Jaw Chuck REF#104 BARBER-COLMAN 16-16, S/N 2745, 51 Sgl Thrd w/90 Deg Hd REF#104 BARBER-COLMAN 16-16, S/N 3171, 53 Dbl Thrd, Spanish Nameplates REF#104 BARBER-COLMAN 16-16, S/N 3580, 59 Dbl Thrd w/Diff & Auto Hobshift REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 3641, 60 Dbl Thrd w/Diff REF#104 BARBER-COLMAN 16-16, S/N 3660, 57 Sgl Thrd REF#104 BARBER-COLMAN 16-16, S/N 4136, Dbl Thrd, C Style End Brace w/Diff REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4170, Dbl Thrd w/Jump Cut Cycle C Style REF#104 BARBER-COLMAN 16-16, S/N 4473, 73 4-Thrd w/Workclamp Cyl C Style REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4520, 75 Dbl Thrd w/Gooseneck Slide REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4631, 79 C Style End Brace, 4W Adj Ctr REF#104 BARBER-COLMAN AHM (36), S/N 1152, 42 Dbl Thrd REF#104 BARBER-COLMAN 16-36, S/N 4090, 66 Dbl Thrd, C Style End Brace REF#104 BARBER-COLMAN 16-36 Multicycle, S/N 4232, 68 Dbl Thrd C Style End Brace w/Diff REF#104 BARBER-COLMAN 16-56, S/N 3136R84, 53 (Reb 84), Dbl Thrd REF#104 BARBER-COLMAN 10-20, S/N 6700045890, 76 Dbl Thrd w/2 Cut Cycle REF#104 TOS OFA Series Conventional Gear Hobbers, 12 & 40 Dia REF#105 TOS OHA Series Conventional Gear Shapers, 12 & 40 Dia REF#105 16-16 Barbara Coleman with differential yr 1970 id 3535 REF#106 Jeil model JDP-2 26 dia. Diff & infeed OB Yr1990 ID 3570 REF#106 Fitchburg spline & pinion 32 OD, 72 REF#106 Liebherr L-301, 12 dia. Yr 1974 id 3465 REF#106 GEAR PINION HOBBERS & SPLINE MILLERS HURTH #KF-32A 15 Dia, 59 Face, 67 REF#103 GE/Fitchuburg Pinion Hob 32 Dia, 72 Face REF#103 MICHIGAN Tool #3237 REF#103 SCHIESS 1 RF-10, 60 Dia REF#103 WANDERER GF 345 CNC Hobbing /Milling Machine 4-Axis 24" Swing x 240 Length REF#103 FITCHBURG Pinion Hobber 42 Dia, 72 Dia REF#103 CRAVEN Horizontal, 18 Dia and 100 Length REF#103 GEAR HOB & CUTTER SHARPENERS (incl CNC) ARTER #A-12, 12 Rotary Surface Grinder for Sharpening Sharper Cutters REF#103 BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, 57 REF#103 BARBER-COLMAN 10-12, 10" Dia, 12" Length, Spark Out REF#103 FELLOWS #6SB, Helical Cutter Sharpener, 6 Dia, up to 50 Degrees REF#103 KAPP #AS-305GT, 1 DP, 28" Grind Length, 10" Diam., Str. & Spiral REF#103 KAPP #AS204GT, 10 Dia, Wet Grinding, CBN Wheels, 82 REF#103 BARBER-COLMAN #3 HS, Hob Sharpener, 4" Max. OD., 4" REF#103 BARBER-COLMAN #4-4HRS, Hob Sharpener, 4" Max. OD. 4" REF#103 REDRING MODEL #SGH "PREIFORM" SHAVE CUTTER GRINDER/SHARPENER REF#103 STAR 6X8 HOB SHARPENER PRECISION GEAR & SPLINE HOBBER REF#103 BARBER-COLMAN 2-2 1/2 , 2.5 Dia REF#103 KAPP #AST-305B, 27.5 Dia, REF#103 KAPP AS-410B REF#103

GEAR ACCESSORIES, PARTS & TOOLING FELLOWS Model #10-4/10-2, All Parts Available REF#102 Tilt Tables for 10-2/10-4, Qty 2 REF#102 FELLOWS Parts Available For All Models REF#103 BARBER-COLMAN PARTS AVAILABLE FOR ALL MODELS REF#103 G&E PARTS AVAILABLE FOR ALL MODELS REF#103 GEAR HOBBERS/CUTTERS CNC LIEBHERR #LC-255 CNC, 6-Axis, 10 Dia, 10 Face, 4 DP, 87 REF#103 PFAUTER #PE-150, 6-Axis CNC, 6 Dia, 5 DP, 6 Face, Fanuc 18MI REF#103 SYKES #H160, 4-Axis CNC Hobber, 6 Dia, All the Features, 93 REF#103 G&E #60 S-2 CNC Gasher/Hobber REF#103 G&E #60SB-2C CNC, Gasher/Hobber REF#103 BARBER-COLMAN #16-36, 16 Dia, 4-Axis, 6 DP, 36 Face REF#103 LIEBHERR #LC-502 6-Axis CNC Gear Hobber, 20" Diam. Cap., Loading REF#103 LIEBHERR #L-652, 5-Axis 26 Dia,27 Face, 2 DP 09 REF#103 MUIR CNC Gear Hobber, 4-Axis, 118 Dia REF#103 LIEBHERR #L-252 3-Axis, 9.8 Dia, recontrolled 2008 REF#103 LIEBHERR #ET-1202 CNC - 70 Dia Internal, Single REF#103 LIEBHERR #ET-1802 CNC 98 Dia Internal, 3-Axis REF#103 MITSUBISHI GD-20 CNC, 5-Axis, 8 Dia REF#103 G&E 120/188, CNC Gasher/Hobber, 188 Dia (5 Meter) REF#103 G&E #120GH, CNC, Gasher/Hobber, Twin Stanchion, 1/2 DP, 42 Face, 94 REF#103 PFAUTER P400H, 5-Axis, 18 Dia, 1 DP, Recontrolled 03 REF#103 G&E #160GH, CNC, Gasher/Hobber, New 07 REF#103 G&E #96GH, CNC, Gasher/Hobber, New 09 REF#103 HAMAI 60SP, CNC 4-Axis, 3.5" OD, 9" Face, 12 DP, New 89 REF#103 PFAUTER PE 300 AW CNC 6-Axis REF#103 GEAR HOBBERS/CUTTERS PFAUTER P1251 Hobbers s/n 25-276 and 25-277 REF#102 PFAUTER (1) RS-00 s/n 17593 REF#102 BARBER COLEMAN (1) 16-36 multi cycle s/n 4404 REF#102 BARBER-COLMAN #16-16, Multi-Cycle, Dual Thread Worm and/or Single Thread Worm REF#103 G&E #48H 48 Dia, 18 Face 2 DP, Universal REF#103 G&E #48H, 48 Dia, 35 Face, 3 DP, Gooseneck Attachment REF#103 LEES BRADNER HH-144 16 Dia, 144 REF#103 BARBER-COLMAN #6-16, 6 Multi-Cycle REF#103 G&E #36H Differential, Excellent Condition REF#103 BARBER-COLMAN #14-30, 14 Dia, 30 Face, 3.5DP REF#103 PFAUTER P-251 10 Dia, 9.6 Face, 4 DP REF#103 BARBER-COLMAN #14-15, 14 Dia, 15 Face, 1 to 4 Start Worm, Several REF#103 BARBER-COLMAN #16-16, 16 Dia, 16 Face, 6DP REF#103

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GLEASON #12 Sharpener, 3-18 Cone REF#103 BARBER-COLMAN 2 1/2-2, S/N 16, 66 Wet w/Auto Feed REF#104 BARBER-COLMAN 6-5, S/N 110R, 55 Wet w/Auto Dress & Sparkout REF#104 BARBER-COLMAN 6-5, S/N 396, 66 Wet w/Auto Dress & Sparkout REF#104 BARBER-COLMAN 6-5, S/N 433, 69 Wet w/Auto Dress & Sparkout REF#104 BARBER-COLMAN 10-12, S/N 643R83, Wet w/Auto Dress, PC Control, Fact Reb 83 REF#104 TOS OHA Series CNC Gear Shapers, 12 & 40 Diameter REF#105 TOS OFA Series CNC Gear Hobbers, 12 & 40 Diameter REF#105 GEAR SHAPERS CNC 36 Shapers, 14 Throat Risers, 53 of Swing, Qty 3 REF#102 FELLOWS #10-4/10-2, Qty 150 REF#102 HYDROSTROKE #50-8, Qty 2 REF#102 HYDROSTROKE #20-8, Qty 5 REF#102 HYDROSTROKE #FS630-125, Qty 1 REF#102 HYDROSTROKE #FS400-90, Qty 2 REF#102 FELLOWS #20-4, Qty 6 REF#102 FELLOWS #48-8Z, Qty 1 REF#102 FELLOWS #FS-180, 3-5 Axis, 7 Dia, 1.25 Face., 6 DP, New 88 REF#103 LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#103 LORENZ # LS-180, 4-Axis CNC, 11 OD, 2 Stroke, 5 DP REF#103 LORENZ #LS-304 CNC Gear Shaper 5-Axis Heckler & Koch Control REF#103 LORENZ #LS-156 CNC Gear Shaper Dia 6 REF#103 FELLOWS FS400-125, 16 Dia, 3.5 DP 5 Face REF#103 SCHIESS RS-20 S, 12 Stroke, 118 Dia REF#103 FELLOWS #10-4 3-Axis (A/B), 10" Dia, 4" Face, 4 DP New .09 REF#103 RP-GS 800 CNC, 4-Axis, Max Dia 31.5, Face 9, 2.5 DP REF#103 RP-GS 400 CNC, 6-Axis, Max Dia 15 Face 4, 3 DP REF#103 STANKO /RPM #48-8 Gear Shaper CNC, Fanuc 18 REF#103 FELLOWS #10-4 2-Axis, 10 Dia 4 Face REF#103 FELLOWS #20-4 3-Axis 10 Dia, 4 Face REF#103 FELLOWS FS400-90 Hydro-stroke Gear Shaper CNC Nominal Pitch 15.7" REF#103 RP-GS 1500 CNC, 4-Axis, Max Dia 49.2, Face 12, 2 DP REF#103 GEAR SHAPERS FELLOWS #10-2, (10 Dia), 2 Face REF#102 FELLOWS #10-4, (10 Dia), 4 Face REF#102 FELLOWS (200) 10-4 / 10-2 Shapers REF#102 FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/ 6 axis 16iMB Fanuc (2009 REF#102 FELLOWS (1) #7 125A Face Gear Machine REF#102 FELLOWS (2) #3 Face Gear Machine REF#102 (1) 4ags with adjustable Helical Guide s/n 30634 REF#102 (1) #7 125A adjustable Helical Guide REF#102 FELLOWS (1) FS630-200 Hydrostroke Shaper s/n 36943 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc Controller (2009) REF#102 FELLOWS (2) Swing-away center support for 10-2 / 10-4 REF#102 FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (2) FS400-170 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis 21i Fanuc Controller (2009) REF#102 FELLOWS (1) 48-8Z Shaper w/ 14 throated riser (53 of swing) REF#102 FELLOWS (1) Horizontal Z Shaper s/n 21261 REF#102 FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB 4 axis Fanuc controller s/n 34326 REF#102 FELLOWS (1) 36-10 Gear Shaper REF#102 FELLOWS (1) 10x6 Horizontal Z Shaper REF#102 FELLOWS (1) 36-6 Gear Shaper w/ 13 riser s/n 27364 REF#102 FELLOWS (1) 10-4 Shaper w/ 3 riser w/ 4 axis 21i Fanuc Controller (2009) REF#102 All Parts for 10-4/10-2 Fellows Gear Shapers REF#102 FELLOWS #36-8, 36 Dia, 8 Face REF#103 FELLOWS #100-8 100 Dia, 8 Face REF#103 FELLOWS #612A, 615A, #645A REF#103 FELLOWS #10-4, 10 Dia, 4 Face, 4 DP REF#103 FELLOWS #4A Versa, 10 Dia, 3 Face, 4 DP, New 70s REF#103 FELLOWS #10-2, 10 Dia, 4 Face, 4 DP REF#103 FELLOWS #20-4, 20 Dia, 4 Face, 4 DP, 70s REF#103 MAAG #SH-100/140, 57 Dia., 12.6 Face, 2 DP, Internal Attachment REF#103 FELLOWS #3-1,/3GS, 3 Max Dia, 1 Face, Pinion Supp, High Precision REF#103 FELLOWS #48-6 INTERNAL GEAR SHAPER ONLY,0-72"OD,6" Face REF#103 LORENZ #SJV00, 7 Dia, 2 Face, 50s REF#103 MAAG #SH-100K 47/12.6/1.7 60s Internal Attachment REF#103

MAAG #SH-150, 57" Dia.12.6" Face REF#103 PFAUTER #SH-180 Shobber 7" capacity hobbing, 9.45" cap REF#103 FELLOWS #36-6 Max Dia 36 6 Face, 3 DP REF#103 FELLOWS #HORZ Z SHAPER, 10 x 6 Dia 27.6 Face 8.5 REF#103 MAAG #SH-75C, 30/8/2.5/52 REF#103 MAAG #SH-600, 235 Dia 36, 1DP REF#103 FELLOWS #4GS & 4AGS, 6 Dia, 2 Face, 4DP, 68, Ref.# Several REF#103 TOS OH-6, Dia 19.7 REF#103 FELLOWS #624A, 18 Max Dia, 5 Face REF#103 FELLOWS #7, #7A, #715,# 75A, #715, #725A, 7 Dia, 0-12 Risers, Several Avail REF#103 MAAG #SH-180-300 , Max Dia 118/ 16.9 Face REF#103 MAAG #SH-350/500, Max Dia 197 REF#103 MICHIGAN #18106 SHEAR-SPEED GEAR SHAPER,14" Dia, 6"Face REF#103 FELLOWS Model Z Shaper, 5" Stroke, 50s REF#103 STAEHELY SHS-605, Gear Shaper REF#103 FELLOWS #6, #6A, #61S, From 18-35 Dia, 0-12 Risers REF#103 FELLOWS #8AGS Vertical Gear Shaper, 8 Dia, 2 Face, 6-7 DP REF#103 TOS OHA50 CNC 5 20 Dia 5 Face REF#105 36-8 Fellows 9 stroke 12 Riser mint yr 1970 REF#106 GEAR DEBURRING/CHAMFERING/POINTING CROSS #50 Gear Tooth Chamferer, 18 Dia, Single Spindle REF#103 CROSS #75 Gear Tooth Chamferer, 10 Dia, 10 Face, 52 REF#103 REDIN #18, 28 Dia, 2, 3, 4 Spindle, Deburrer/Chamfer, PLCs, Tilt Table REF#103 REDIN #20D, 20 Dia, Twin Spindle, Deburrer/Chamfer REF#103 SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14 Dia, 5 Face, 82 REF#103 SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10 Max Dia, (3) New 96 REF#103 REDIN #24 CNC Dia 4 Setup Gear Deburring REF#103 CROSS #60 Gear Tooth Chamferer, 10 Dia, Single Spindle REF#103 FELLOWS #100-180/60 CNC Max Dia 180, Single Spindle REF#103 CIMTEC #50 Finisher REF#103 RPM #GC-500 CNC 20 Dia, Single Spindle REF#103 CROSS #54 Gear Deburrer, 30 Dia, 18 Face REF#103 RED RING #24 Twin Spindle Dia 4 REF#103 CROSS #55 Gear Deburrer, 18 Dia, 1.5 Spindle REF#103 GLEASON GTR-250 VG CNC 5-Axis REF#103 GRATOMAT #300L REF#103 GEAR Honers Fassler #K-400 CNC Hone 16" Dia REF#103 Fassler K-400A CNC Hone 16 Dia REF#103 Kapp #CX120 Coroning 4.7 Dia REF#103 Red Ring GHD-12, 12 Dia, 5.5 Stroke REF#103 Red Ring GHG, 12 Dia, 5.5 Stroke REF#103 Kapp #VAC65 Coroning 10 Dia REF#103 GEAR SHAVERS Red Ring #GCX-24" Shaver, 24 Dia, 33 Stroke REF#103 Red Ring #GCU-12, 12 Dia, 5 Stroke REF#103 Red Ring #GCU-8 Shaver. 8 Dia REF#103 Red Ring #GCY-12, 12 Dia, 5 Stroke REF#103 Red Ring GCI 24, 12.75 Dia, 5 Stroke REF#103 Nachi Raso CNC Shaver, 3-Axis REF#103 Michigan #873-24A, 24 Dia, 15 Face, 2 DP REF#103 GEAR GENERATORS, STRAIGHT BEVEL GLEASON #37 Str. Bevel Planer, 6 Dia REF#103 GLEASON #54 Str, Bevel Planer, 60 Dia REF#103 GLEASON #496 Straight.& Spiral. 7.5 Dia REF#103 GLEASON 14, Coniflex Straight Bevel REF#103 GLEASON 24A Straight Bevel REF#103 GLEASON 725-Revacycle, 6 Dia REF#103 GLEASON 726-Revacycle, 5 Dia REF#103 GLEASON 2A, 16 Cone REF#103 GLEASON #116, 9 Cone, 2.75 Face REF#103 GLEASON #104 w/Helical Motion, Coniflex, Straight Bevel REF#103 GEAR GENERATORS, SPIRAL BEVEL (HYPOID) GLEASON #645 Hypoid Generators REF#103 GEAR GRINDERS CNC HOGLUND, Model #264, CNC Internal Gear Grinder REF#103 KAPP #VAS-482 CNC GEAR GRINDER, 11.8" SWING DIA REF#103 GLEASON Phoenix 200G Hypoid Grinder CNC REF#103 REISHAUER RZ-801 CNC, 31.4 Dia REF#103 NILES ZSTZ 06-800 CNC, 31.5 Dia, 11 Face REF#103 NILES ZSTZ 08-800 CNC, 32 Dia, 11 Face REF#103

RED RING #SF-500 CNC Int/Ext, 26 Dia, REF#103 GLEASON/TAG 400 CNC, 16 Dia REF#103 HOLFER PROMAT 200 , 7.87 Dia CNC Gear Grinder REF#103 GEAR GRINDERS #27, #137, and #463 Gleason Hypoid Spiral Bevel gear grinder generating Cams (2 full sets) REF#102 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102 REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#103 RED RING #SGJ-18, 18 Dia., 9 Face, Internal Attachment, New 78 REF#103 DETROIT Gear Grinder #GGI-16x3A, Internal Gear Grinding, 16" OD REF#103 MAAG SD-32-X REF#103 GLEASON #463, 15 Dia REF#103 HOFLER BHS H1603-2000, 78.7 Dia REF#103 NILES ZSZT-3500, 139 Dia REF#103 KAPP VAS #331, Gear Grinder REF#103 NILES ZSTZ-1250/5000 49.2Dia REF#103 GEAR RACK MILLERS/SHAPERS MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#103 SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, 80 REF#103 SYKES VR-60 Vert Rack Shaper, 60 Cut Length, 4DP, Stroke 4 REF#103 GEAR THREAD & WORM, MILLERS/GRINDERS LEES BRADNER #HT 12x54, Dia 12 /54 REF#103 MOREY-SHIELDS THREAD MILLER, Dia 12 REF#103 BARBER-COLMAN #10-40, 10" Dia., 40" Length, 4 DP REF#103 EXCELLO #31L, External Thread Grinder, 5" OD, 20" Grind Length REF#103 EXCELLO #33 Thread Grinder 6 Dia 18 Length REF#103 EXCELLO #35 and #35L Thread Grinder, 84" Between Centers REF#103 EXCELLO #39 Int. Thread Grinder, 9.5" Max Dia., 10" Max. Swing REF#103 HURTH #KF-33A Multi-Purpose Auto-Milling Machine 88 REF#103 LEES BRADNER #HT12x102, Extra Large Capacity REF#103 J&L AUTOMATIC THREAD GRINDER, 6" X 36", 38 REF#103 LEES BRADNER #HT 12"x 144" Thread Mill, 12" Dia, REF#103 WALDRICH COBURG WHIRLING, 3 Dia, 118 Length REF#103 LEES BRADNER # LT 8 x 24 8 Dia REF#103 HOLROYD 5A 24.8 Dia REF#103 HECKERT WMW #ZFWVG REF#103 LEES BRADBER WORM MILLER REF#103 GEAR TESTERS/CHECKERS (incl CNC) FELLOWS (1) RL-600 Roll Tester s/n 35814 REF#102 FELLOWS (1) 24H Lead Checker s/n 32289 REF#102 GLEASON (1) #14 Tester s/n 31907 REF#102 GLEASON (1) #6 Tester s/n 19316 REF#102 FELLOWS (1) 20 M Roller Checker REF#102 FELLOWS (1) 20 M w/ 30 Swing Roller Checker REF#102 FELLOWS (1) #8 Micaodex s/n 36279 REF#102 David Brown #24 Worm Tester REF#103 Fellows 12H Gear Tester REF#103 Fellows #12M Gear Tester REF#103 Fellows 20M Gear Tester REF#103 Felows #24 Involute Measuring Instrument REF#103 Gleason #4, #6, #13 and #17 Testers REF#103 Hofler EMZ-2602 Int/Ext Gear Tester 102 REF#103 Klingelnberg #PFSU-1200 Gear Tester REF#103 Klingelnberg #PFSU-1600 Gear Tester-2001 REF#103 Klingelnberg PWF-250 Tester REF#103 Kapp Hob Checker WM 410 REF#103 Maag #ES-430 Gear Tester REF#103 Maag #SP-130 Lead and Involute Tester REF#103 National Broach Gear Tester GSJ-12 REF#103 Oerlikon #ST2-004 Soft Tester REF#103 Maag #SP-60- Electronic Tester REF#103 Parkson #42N Worm Gear Tester REF#103 Fellows #24H Tester REF#103 Gleason #104 Tester REF#103 Vinco Dividing Head Optical Inspection REF#103 MISCELLANEOUS WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80 Centers, 12 Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965 REF#101 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102 GLEASON #529 Quench, 16" Diameter REF#103 VERTICAL TURNING LATHES AND MORE - Please Check Our Website To View Our Entire Inventory REF#103 TOS SU & SUS Series Conv Lathes REF#105 TOS SUA Series CNC Flat-Bed Lathes REF#105

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WE MANUFACTURE BROACHES & RELATED TOOLING FOR ANY BROACH MACHINE

SHARPENING OR RECONDITIONING ALsO PRODUCTION BROACHING
We Weld Broken & Chipped Broaches

GEAR GRINDING SERVICES

Gear cutting from raw material to finished parts Ground tooth gears and pinions to 1 D.P. and up to AGMA quality class 13
From 1 Diameter, 64 D.P. to maximum sizes listed
Spur Gears Helical Gears Spur &Helical Gears, Crown Hobbed Internal Gears &Splines Ground Gears, Crowned or Straight Herringbone Gears, Center Grove

THINFILMCOATINGS
HSS &Carbide up to 5 Dia. Straight Gash, Sharpened &Inspected Per AGMA STANDARDS Quick Turnaround

HOBSHARPENING (763) 425-5247

Max. Face
24 24 22 8 20.5 14

Max.Size
92 P.D. 72 P.D. 72 P.D. 100 P.D. 72 P.D. 36 P.D.

Max. Pitch
1 D.P. 1 D.P. 1 D.P. 1-1/4 D.P. 1 D.P. 2 D.P.

BROACH HOUSE MFG., INC.

We Have Used Broaches In Stock
11383 Route 166 Marion, I L 62959 618-993-3530 Fax:618-997-9158 e-mail: broach_house@mychoice.net

KORO SHARPENING SERVICE

9530 85th AVENUE NORTH MAPLE GROVE, MN 55369 info@koroind.com

2182 E.Aurora Rd., Twinsburg, OH 44087 Phone: (330) 425-4419 Fax: (330) 425-8600 www.mwgear.com E-mail: sales@mwgear.com

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Gear Hobbing, Sharpening, and Roll Testing Machines Rebuilds / Retrofits and Spare Parts Services

Need spare parts and machine services for your obsolete MIKRON Model 132, 102, A33, or A21 gear hobbers, or A60 Hob Sharpener, or 1R, 2R, 3R Gear Roll Testers?
Machine trade-in and re-build services  Spare Parts & New Replacement parts for: Hobbing Spindles 8.0 or 10mm, Hob Cutters, Hob Arbors, Centers, Work-holding Collets, Geared Drives, Motors, Change Gears and Phenolic Gears  Electronics & Controls upgrades & Retrofits: Drive motors, PLC and solid state electronics only or- new PC based Controller and Servo Drives  New Rigid High Speed CNC gear hobbers to cut gears and splines up to 50mm / 2 & 100mm/ 4 ODs, up to 16,000 rpm hob spindle & 5,000 rpm work spindle speeds: ideal for dry Carbide hob cutting.  Replacement parts for Model 1R & 2R gear roll testers, arbors, master gears or NEW granite bed gear roll tester with WinGear (r) PC based gear roll test controller and analysis software. For prices and deliveries today Call 1-877-567- GAGE (4243) or email: sales@parkerind.com

MARKET
Manufacturing excellence through quality, integration, materials, maintenance, education, and speed.

PLACE

GEAR CUTTING TOOLS SHAPER CUTTERS HOBS-HSS AND CARBIDE SPECIAL PURPOSE TOOLS SPLINE GAGES BROACHES THREAD MILLING CUTTERS SPLINE ARBORS HELICAL GUIDES FOR GEAR  SHAPING MACHINES

NEW! TOOL COAtINGS-cHOIcE OF StANDARD AND OUR PROPRIEtARY cOAtINGS  NEw! TOOL SHARPENING AND REcONDItIONING  Gear ROLL Testers with WinGear PC Test and EVALUATIoN SofTwARE MASTER GEARS

STOR-LOC MODULAR DRAWER SYSTEM

880 N. Washington Ave. Kankakee, IL 60901 Toll Free: 1.800.786.7562 Fax: 1.800.315.8769 email: sales@storloc.com

www.storloc.com

PARKER Industries Incorporated 1650 Sycamore Avenue Bohemia, NY 11716 TOLL FREE 1-877-567-GAGE T: 631-567-1000 | F: 631-567-1355

W: parkerind.com

for your Master Gear & Spline Gaging needs

Technical Solutions Aerospace and Automotive Applications

Multiple Start Gear Grinding Wheels

Lower grinding forces New abrasive blends & bonds Lower grinding temperatures Increased porosity for higher stock removal

Gear Honing Benefits

Flank correction Reduced operating noise Longer service life Correction for distortion from hardening process

Call 1-877-567-GAGE (4243) or email: sales@parkerind.com

Hermes Abrasives, Ltd.
524 Viking Drive Virginia Beach, VA 23452 Toll free phone: 800.464.8314 PO Box 2389 Virginia Beach, VA 23450 Toll free fax: 800.243.7637

JULY 2010

61

< Continued from page 56

New NBV Vertical Machining Center from MAG

The new NBV vertical machining center is as noteworthy for what it doesnt have as what it has. Eliminating all hydraulics, this compact VMC is flush with modular application flexibility, including configurations for three-, four-, and five-axis contouring or fiveaxis mill/turn work, integrated CAM support and program simulation, and four spindle options ranging up to 42,000 rpm. In addition to its hydraulic-free design, the NBV conserves energy with a selectable ECO-Mode power saving feature that automatically levels speed and acceleration for an ideal balance of cutting performance, energy use, and machinecomponent life. Ideal applications include die/mold, automotive and aerospace impellers and blisks, medical, and general machining. Control options for the NBV 400 include Siemens, Bosch Rexroth, Fanuc and Heidenhain. The NBV 400 is a self-contained unit, making for easy transportation, rigging and setup. Automation and other processing options, including MQL/dry machining, robot load/unload systems and additional tool-disc magazines, are easily integrated. Learn more by visiting IMTS booth # E-5515 or going to [www.mag-ias.com].

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advertiser INDEX
ALD Thermal Treatment Inc..................................................... 11 Allen Adams Shaper Services..................................................60 AWEA. .......................................................................................55 B&R Machine and Gear Corp.................................................. 21 Beavermatic Inc....................................................................... 41 Bourn & Koch...........................................................................63 Broach House Mfg. Inc............................................................60 Carolina Gear & Components, Ltd...........................................23 Chamfermatic Inc.....................................................................29 Cincinnati Gearing Systems.....................................................37 Clifford Jacobs Forging Co......................................................43 DT Technologies CZ sro. ..........................................................29 eldec Induction USA................................................................40 Excel Gear................................................................................60 Gear Manufacturing Inc...................................................... 61,62 Gear Motions Inc......................................................................60 Gleason Corporation.............................................................. IFC Hanik Corporation....................................................................63 High Performance Gear Inc. .....................................................28 IMTS 2010................................................................................59 Hermes Abrasives Ltd.............................................................. 61 Innovative Rack & Gear Co......................................................60 J L Becker Co..........................................................................40 KISSsoft USA LLC...................................................................46 Klingelnberg GmbH....................................................................2 Koro Sharpening Service.........................................................60 Loudon Industries Inc. .............................................................. 51 MicroGear................................................................................ 14 Midwest Gear Corp..................................................................60 Mitsubishi Heavy Industries America Inc................................BC Mound Tool Co. ........................................................................46 National Bronze & Metals Inc. ..................................................49 New England Gear.....................................................................7 Overton Chicago Gear............................................................. 13 P&G Machine & Supply Co Inc................................................ 61 Parker Industries...................................................................... 61 Process Equipment Company................................................. 10 Proto Manufacturing Ltd.......................................................... 12 R P Machine Enterprises Inc...............................................32-33 Raycar Gear & Machine Co.....................................................50 Repair Parts Inc........................................................................ 51 Riverside Spline and Gear Inc. .............................................. 9,31 Sakuni USA..............................................................................60 Sandvick Coromant. ...............................................................IBC Solar Atmospheres. ..................................................................45 Stor-Loc............................................................................... 52,61 Surface Combustion................................................................ 19 The Broach Masters...................................................................4 The Cincinnati Steel Treating Co.............................................44 The Company Corporation. ......................................................60 TMFM LLC...............................................................................50 Toolink Engineering....................................................................1 Walker Forge Inc......................................................................44 Willman Industries....................................................................49

COMPANYNAME.................... PAGE NO.

Booth# N6924

www.hanikcorp.com

CORPORA TION

JULY 2010

63

Q&A
Trace Hill
preSident
LoUdon IndUStrieS, Inc.
relationships with our customers that are built on trust, mutual respect, and a proven track record. We know what they need, and they know what we can do for them. Those types of relationships have really helped us weather the recent economic downturn, too. We took a hit like everybody else, including our clients, and even when they had to downsize and reduce their orders they still gave us everything they could, which made all the difference. I cant think of a single customer who left us during that time, which really means a lot to us. We had to trim back our operations a little, but were rebounding, and we have a really positive outlook on the future. And Im proud of what weve built together. My sons work here, and weve launched three companies, so this truly is a family run operation. what they do, so theyre a great resource for us to have. As for quality control, were ISO certified and have our own QC lab thats equipped with a Zeiss PRISMO CMM with gear-checking capability. Its a terrific machine, and I really have nothing but good things to say about Zeiss. Our customers feel the same way, too, and sometimes knowing that we have a Zeiss machine is all they need to know about our quality. Still, well check their parts at any stage in the process they need us to, and well do a final inspection at whatever level they require and send them the paperwork for their records. We also provide engineering services to our customers who need them. We can work straight from the plans theyve created themselves, or we can work with them to develop drawings

GS: Tell us how you came to found the company. TH: In the early days we were just doing subcontract work, taking on anything we could handle just to keep the doors open. Then one of our clients needed us to manufacture gears for overhead hoists, and that was a real education in terms of the nomenclature, the processes, and the types of equipment wed need, so from about that time on we began specializing in spur, helical, and splines, cutting both internal and external teeth on all three. Our basic rule in terms of size is that if a person can pick it up, we can make it. GS: Describe the markets you serve, and your relationship with your customers. TH: Were involved in construction, transportation, and a little agriculture. Most of our customers are found throughout the United States and Canada, and we rely on our own inside sales staff. Gearing is a pretty specialized industry, after all, and people will spot it right away if you dont know what youre talking about. We try to be as diversified as we can, and our goal is that no one customer should represent more than 10 percent of our revenue. We also seek customers who arent doing what we do, so that we dont become an overload facility where the work is sporadic and dries up unexpectedly. The good thing is that weve developed longstanding

Weve developed longstanding relationships with our customers that are built on trust and mutual respect. We know what they need, and they know what we can do for them.
GS: What other services do you provide, such as heat treating and quality control? TH: While we have the volume to justify doing heat treating ourselves, we have relationships in place with companies that are so good at what they do that wed rather continue relying on their expertise. Probably 85 percent of the parts we manufacture require heat treating, but these guys are the very best at for the part they need and then handle all the prototyping and detailing. And if theres a particular type of test stand needed for their part and we dont have it, we'll either build it ourselves or go out and get it. Whatever level of assistance our customers require, were prepared to deliver it, because we want them to understand from the very first order that we take what they do as seriously as our own work.

To learn More:
Call (888) 776-2546, e-mail sales@loudonindustries.com, or go to [www.loudonindustries.com].

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Booth# N6837