COMPANY PROFILE:
ALLEN ADAMS
SHAPER SERVICES, INC.
CARBURIZABLE STEELS
CARBURIZABLE STEELS
OPTIMIZATION OF
JANUARY 2015
Your Resource for Machines, Services, and Tooling for the Gear Industry
JANUARY 2015
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Knig
Transmission Housing
720 lbs
JANUARY 2015
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40
From the ashes of Fellows Corporation rose Allen Adams Shaper Services, Inc.,
which has been serving companies and people in need of gear shaping services
and machine repair since its inception in 2002.
By S.R. Hipsley and R.J. Davey, PhD Engineering, and R.T. WhewayThis paper discusses
software that automatically generates a 3-D meshed finite element model of a
helical gear set, which does not require the gear designer to have a knowledge
of finite element analysis.
JANUARY 2015
Departments
08 INDUSTRY
NEWS
Gleason enhances GMS series
of analytical gear inspection
systems with the new 175 GMS
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.
18 MATERIALS
MATTER
Fred Eberle
13
49 PRODUCT
SHOWCASE
American
Gear Manufacturers
Association
56 Q &A
Jeanine Kunz
SME
20 TOOTH
TIPS
Stephen P. Radzevich
HOT
24 SEAT
Jack Titus
26 TREND
TALKS
Anna Claire Conrad
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
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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.
JANUARY 2015
VOLUME13 / NO. 01
JANUARY 2015
LETTER FROM
THE EDITOR
David C. Cooper
PUBLISHER
Chad Morrison
ASSOCIATE PUBLISHER
EDITORIAL
Is it just me, or did 2015 come out of nowhere? Even though I typically look forward to the new year, I cant
help feeling a little blindsided this time around.
2014 was an awesome year for me. I mean, it was my year. I graduated from Auburn University in a field
Im passionate about and love, moved into my own one-bedroom apartment, got an incredible job within weeks
of earning my degree, and became engaged to the man of my dreams.
I guess you could say I grew upfast.
But I enjoyed every second of itevery laugh, cry, hug, and tiresome, been-up-all-night-studying-for-my-lastcollege-exam-ever yawn. It was an incredible year, and even though it flew by, itll be tough to beat.
Whenever I try something new, I get the same feeling in my gut I had the first time I jumped off a high-dive.
Its those butterflies everyone talks about mixed with every fear and food aversion youve ever had, and theyre
all gurgling inside your stomach simultaneously. Its a difficult sensation to overcome, but once you do, that rush
of adrenaline makes you want to do it over and over again. Thats exactly how I feel going into this new year.
Thats why Im apprehensive going into 2015, and I imagine you are too. 2014 was a growing year for the
gear manufacturing industry as it bounced back from the dark age of 2013. A lot of companies saw their activity drop quite significantly that year, but were able to pick it back up in 2014. As we discussed in last months
Trend Talks column, going into the new year, businesses are hoping for orders and bookings to be up by at least
5 percent, which seems feasible since they were up by 15 percent last year.
This issue defends that belief that things are only going to get better. In this months Trend Talks and Q&A,
with the help of SMEs Jeannine Kunz, we discuss how vital education, workforce development, and human
capital are to this industry. There, we provide important dates and resources where you can learn more about
those opportunities for you and your employees. Youll also read about Allen Adams Shaper Services in our
Company Profile and see how theyve been doing things right since 2002.
We also provide pieces discussing what to look forward to in 2015, including AGMA and ABMAs big event
being held in the wine country of Napa, California, and two technical papers that were discussed at last years
Fall Technical Meeting in Arlington, Virginia. One focuses on an application to optimize metallurgy and
improve the performance of carburized steels, while the second discusses how to optimize gear tooth contact
by means of helix angle modification.
As always, the information youll read about in this issue will also be available online, in the Gear Solutions app,
and on our 2015 calendar.
Last year was great, and it was my year, but 2015 will be even better, and itll be mine, too.
Thanks for reading, and Happy New Year!
Anna Claire Conrad
Stephen Sisk
EDITOR
SALES
Chad Morrison
ASSOCIATE PUBLISHER
CIRCULATION
Teresa Cooper
MANAGER
Kassie Boggan
COORDINATOR
Jamie Willett
ASSISTANT
ART
Jeremy Allen
CREATIVE DIRECTOR
Michele Hall
GRAPHIC DESIGNER
CONTRIBUTING
WRITERS
A. ASPHAHANI
R.J. DAVEY
FRED EBERLE
J. GRABOWSKI
S. R. HIPSLEY
C. HOUSER
MADELAINE MORGAN
STEPHEN P. RADZEVICH
J. SEBASTIAN
D. SNYDER
K. TASKIN
JACK TITUS
Vertical Logo
gearsolutions.com
Coop w
20-4 IN STOCK
Remanufactured in 2014
www.newenglandgear.com
INDUSTRY
NEWS
New Products,
Trends, Services,
and Developments
______________________
www.gleason.com
______________________
Gleason Corporation announces the introduction of the 175GMS Analytical Gear
Inspection System, with faster complete
inspection of automotive, aerospace and
other smaller gears, as well as gear cutting
tools and non-gear parts.
The latest addition to the GMS Series with
models available for gears up to 3,000 mm
in diameterthe 175GMScompletes the
development of the GMS series and replaces
Companies wishing to submit materials for inclusion in Industry News should contact the Managing Editor Anna Claire Conrad at editor@gearsolutions.com. Releases accompanied by color images will be given first consideration.
gearsolutions.com
_____________________
GMTA has formed an alliance with Star
SU LLC in Hoffman Estates, Illinois to
manufacture Scudding tools for the North
American market. Scudding is the radical
improvement on traditional power skiving
technology for gear production, long proven
in the market to be faster, more accurate
and versatile in use. Often thought to be
limited to internals only, Scudding is fast
beginning to compete in certain applications
with hobbing on external gears and splines,
as well.
David Goodfellow of Star SU
signed the agreement with GMTA president
Walter Friedrich and VP Scott Knoy.
-GMTA continues to expand its representation of K + G (Kristen + Gormann),
a tooling manufacturer in Germany that
supplies the industry with products for inside
grooving, turning, profile milling, facemilling, geartooth milling, chamfering and
Spline Milling on
Traditional CNC Equipment
Utilizing custom ground form inserts and standard
precision ground tool bodies with a precise insert locking
and locating system, TMFM LLC can turn spline hobbing
operations into a true milling scenario!
KISSsoft Highlights
Multi-Industry Solutions
earSol_KISSsoft_Rel_03_2014_Highlights_92_25x123_83mm.indd 1
OILFIELD
AUTOMOTIVE
AEROSPACE
tmfmllc.com 1.877.SPLINE.5
JANUARY 2015
5/5/2014 10:57:35 AM
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gearsolutions.com
Phone: 815.874.3948
www.raycargear.com
sales@raycargear.com
_____________________
www.kapp-niles.com
_____________________
R&P Metrology GmbH announced the successful completion of acceptance trials of a
new RPG 3500DS at their Aschaffenburg,
Germany, facility. The machine, a four axis
(+1) generative gear inspection systems capable
of measuring parts of up to 3,500mm (4000mm
optionally) in outside diameter, was delivered to
a customer in Germany.
Utilizing the basic design and construction of the transportable R&P Metrology PM
750/1250, the RPG 3500DS has an active
air suspension system and does not require a
special foundation. The use of dark granite
provides excellent temperature stability that
enhances inspection accuracy and repeatability.
The RPG 3500DS comes with state-of-the-art
technologies like air bearings, linear motors,
direct drive hydrostatic rotary table, newly
designed operator friendly keyboard with touch
screen, and the unique RP Utilities software for
JANUARY 2015
11
_____________________
www.liebherr.com
_____________________
Liebherr has developed a gear-hobbing
machine that applies a multi-cut strategy,
including press deburring. Continual loading and press deburring occur in parallel
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American
Gear Manufacturers
Association
Madelaine Morgan
Director of Meetings
www.agma.org
and opportunities to bring home the latest best practices from fellow gear and
bearing industry executives. The planning committee has created a meeting
experience that is sure to prepare you
and your businesses for the coming years.
In addition to the educational sessions,
it will be a great time to engage in dialogue with your peers and find the latest
and greatest of our industry in the postrecession era.
The speaker line-up for the meeting is
top-notch. The topics will both inspire
you and provide you, your company and
colleagues with much-needed updates
and knowledge on several important
business related topics.
This year, we look at some new top-
13
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gearsolutions.com
In Nara, the delegation visited the Toai-ji shrine, location of the worlds largest bronze statue of Buddha.
CALENDAR OF EVENTS
Whether youre looking for technical education, networking opportunities, or a way for your voice to be heard in the standards process,
AGMA has something to offer you. If you would like more information on any of the following events visit
www.agma.org or send email to events@agma.org.
FEBRUARY
JANUARY
**Events are open to AGMA members only. Not a member? Send e-mail to membership@agma.org.
Mill Gearing Committee Meeting January 6, 2015 WebEx
Helical Gear Rating Committee Meeting January 7, 2015 WebEx
Powder Metallurgy Gearing Committee Meeting January 13, 2015 WebEx
Wormgearing Committee Meeting January 14, 2015 WebEx
Bevel Gearing Committee Meeting January 15, 2015 WebEx
Enclosed Drives for Industrial Applications Committee Meeting January 15, 2015 WebEx
Mill Gearing Committee Meeting January 16, 2015 WebEx
Fine Pitch Gearing Committee Meeting January 20, 2015 WebEx
Metallurgy & Materials Committee Meeting January 20, 2015 WebEx
Gear Accuracy Committee Meeting January 21, 2015 WebEx
Cutting Tools Committee Meeting January 22, 2015 WebEx
Enclosed Drives for Industrial Applications Committee Meeting January 22, 2015 WebEx
Helical Gear Rating Committee Meeting January 23, 2015 WebEx
Plastics Gearing Committee Meeting January 26-27, 2015 Ft. Myers, FL
Technical Division Executive Committee Meeting January 28-29, 2015 Orlando, Florida
Nissei Corporation
Nissei is a manufacturer of high precision gears and
gear motors located in Aichi. Nissei is a business division of Brother Industries.
Yutaka Seimitsu Kogyo, Ltd.
Yutaka is a wholly owned subsidiary of Toyota Motor
Corporation and located in Seto City.
In addition to visiting the companies, participants were
able to visit many popular sights around the country.
The group enjoyed the sights of Toyko, including a visit
to the famous Ginza district and the Tsukiji fish market.
While visiting Kyoto, they visited the beautiful Kinkakuji or Golden Temple, a tour of the Gekkeikan Sake
Museum, and the Fushimi Inari-Taisha shrine.
JANUARY 2015
15
American
Gear Manufacturers
Association
(703) 684-0211 |
www.agma.org
STAFF
Kenneth J. Flowers: Owner and Vice President, Machine Tool Builders, Inc.
Bill Gornicki: Vice President Sales & Marketing, ALDHolcroft Vacuum Technologies Co., Inc.
BOARD OF DIRECTORS
EXECUTIVE COMMITTEE
AGMA LEADERSHIP
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
16
gearsolutions.com
Celebrating Our
Diamond Jubilee...
Were Just Getting Started.
MATERIALS
MATTER
Fred Eberle
Technical Engineer
Hi-Lex Automotive Center
This month we are going to discuss several critically important factors designers
need to know when developing an application with molded plastic gears.
A DESIGNER NEVER WANTS TO MOLD
Note: There are other factors that are beyond the scope of this document, but those may be incorporated in future articles.
ABOUT THE AUTHOR: Fred Eberle is a technical specialist in the development of gearing, drive motors, and power closure devices in the
automotive industry. He currently serves on the AGMA Plastic and PM Gearing Committees. Eberle has authored several papers on gearing,
measurement system analysis and process statistics. He can be reached at Fred_Eberle@hci.Hi-Lex.com.
18
gearsolutions.com
JANUARY 2015
19
P. Radzevich
TOOTH Stephen
Sr. Product Engineer
TIPS
Eaton Corporation
simplified approach can be used for the development of the CAD models of the gear and the pinion
in the right-angle bevel gear set under consideration. This approach is based on the schematic shown
in Figure1.
Using commercial software ProE, base cones of the gear and the pinion were constructed according
to Figure1. Then, a plane tangent to both base cones was constructed. This plane is the plane of
action, PA A circular arc of the radius Rlc=200mm is drawn within the plane of action so that it intersects the middle circle of the PA at the angle equal to 90 _ylc=80. The tooth flanks G and P of the
gear and the pinion were generated as the corresponding families of the desirable line of contact,LCdes,
in its motion in relation to a reference system associated with the gear (for the CAD model of the
bevel gear), and in its motion in relation to a reference system associated with the pinion (for the CAD
model of the bevel pinion). Use of the discussed approach enables one to develop CAD models of the
gear and the pinion in the right-angle bevel gear set (Fig.3).
Figure 1: Generation of the tooth flank of the geometrically accurate bevel gear, G
Known formulae and equations derived for bevel gears are also valid for gears with a large tooth count and not vice versa.
This equation was proposed by Prof.Shishkov as early as in 1948 (or even earlier) in his paper:Shishkov,V.A.,Elements of Kinematics of Generating and Conjugating in Gearing,in:Theory and Calculation of Gears, Vol.6,
Leningrad: LONITOMASH, 1948. In detail, this equation is also discussed in the monograph: Shishkov,V.A.,Generation of Surfaces in Continuously Indexing Methods of Surface Machining, Moscow, Mashgiz, 1951, 152pages.
ABOUT THE AUTHOR: Stephen P. Radzevich, Ph.D. is with the Innovation Center in the Eaton Corporations automotive business segment. He
can be reached at (248) 226-6831 or stephenpradzevich@eaton.com.
20
gearsolutions.com
bevel gears of the developed design was investigated in comparison to that of the similar
gear set cut using Gleason method of gear
generating. The comparison is performed
based on the developed CAD models.
Predicting the contact geometry of the tooth
flanks. When a bevel gear tooth flank is
generated following Gleason method of gear
generating, the contact patch (Fig. 7) is of
LXRD
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Figure 4: Tooth flanks G and P of the gear and the pinion are always in line contact with each other.
Figure 6: The gear and the pinion in the right-angle bevel gear set cut on a 5-axis NC machine
22
gearsolutions.com
IN CONCLUSION:
Bevel gears with a novel geometry of the tooth flanks are discussed
in the paper. Three requirements which geometrically accurate
gearing must meet are outlined. Gearing of the proposed design
Figure 7: Contact patch under a low and high load in gears cut by Gleason
method.
e-mail: tywarner@peoplepc.com
JANUARY 2015
23
HOT
SEAT
Jack Titus
ABOUT THE AUTHOR: Hot Seat columnist Jack Titus has an additional column in Thermal Processing for Gear Solutions, in which he discusses
scheduled maintenance of furnaces, distortion control, and low-pressure carburizing. Jack Titus can be reached at (248) 668-4040 or
jtitus@afc-holcroft.com. Go online to www.afc-holcroft.com or www.ald-holcroft.com.
24
gearsolutions.com
TREND
TA L K S
Associate Editor
Gear Solutions Magazine
In the wake of the New Year, gear-manufacturing institutions across the globe are
making continuing education and training a priority for 2015. This is resulting in a
more qualified workforce, leading to better products and services.
GROWING UP, MY PARENTS made sure
ABOUT THE AUTHOR: Contact Anna Claire, associate editor, Gear Solutions (205) 380-1573 ext. 205.
26
gearsolutions.com
COMPANY
PROFILE
28
gearsolutions.com
From the ashes of Fellows Corporation rose Allen Adams Shaper Services, Inc., which has
been serving companies and people in need of gear shaping services and machine repair
since its inception in 2002.
By Anna Claire Conrad
As people embark on new adventures in 2015, many are met
with the frustration of sticking to their resolutions. Some people
may want to lose some weight before spring arrives, and there
may be others who hope to be more frugal with their annual
expenses. Then, there are those who hope to improve on their
character by being more dependable and honest. Luckily for Allen Adams Shaper Services, Inc., those qualities have been at its
core since its inception in 2002.
We just want people to know that were trustworthy, Allen
Adams, president and owner, said. We supply qualified service
and repair parts for their machines. We will fill their order and
get it back to them when they need it. More importantly, when I
tell them something, Im telling them the truth. Im not pulling
their leg or jerking them around. Its what I truly believe.
With approximately 10 employees working out of its one facility in Proctorville, Vermont, and one serviceman who travels
across the country, its sense of character and morale is what has
made Shaper Services the success it is today with a customer
base reaching all across North America.
We make repair parts as well as service machines, and we
serve anything from aircraft to heavy equipment to automotive, just the whole range, Adams said. We are also able to
completely rebuild machines in our shop. Some of our customers
include Curtis Wright, Southern Gear, Allison Transmission,
Caterpillar, GM, and Ford. We travel all around repairing machines, and we also do a lot of that in the shop.
Its always interesting to come across a small company with
a reach as broad as Sharper Services, and that is in part due
to its connection to the former Fellows Corporation, originally
dubbed Fellows Gear Shaper Company in 1896 by its founder
Edwin R. Fellows.
Once a titan in the gear shaping and service industry that survived the Great Depression and two world wars, it fell apart in
2002 after being acquired by the Emhart Corporation in 1974
and then by Goldman Industrial Group in 1984. Goldman filed
for bankruptcy in 2002 and in July of that same year, Bourn &
Koch, Inc., of Rockford, Illinois, acquired the gear shaper machine tool manufacturing assets and the gear shaper and StarSU, Inc., of Hoffman Estates, Illinois, acquired the cutting tool
manufacturing assets.
However, where Fellows fell, Shaper Services stood tall.
We opened our doors right after Fellows closed theirs, Adams said. Since then, weve started out doing exclusively service
JANUARY 2015
29
QuesTek Innovations LLC has successfully designed and developed four new steels
that can be used in gearing applications, two of which have been implemented
in demanding gear and bearing applications in ground and aerospace military,
commercial aerospace, high-performance racing, oil and gas, and other industries
INTRODUCTION
Q u e s Te k
I n n ovat i o n s
L LC
(QuesTek) of
Evanston, IL
uses its proprietary Materials by
Design expertise and technology
in conjunction with its ICME-based
methodologies to rapidly design,
develop and qualify advanced
alloys into demanding applications.
Accelerating the historically slow
and expensive materials design and
development process, QuesTeks
approach integrates extensive
thermodynamic and kinetic databases
with advanced computational modeling
tools to develop and optimize precise
chemical compositions and processing
parameters ensure specified property
targets and meet desired performance
goals.
Optimization of design
demands consideration of tradeoff in
materials properties, necessitated by
competing requirements.
QuesTek has computationally
designed and developed many new
ultra-high-perfor mance alloys,
Typical alloy properties
EI, %
RA, %
Achievable
Fracture
surface hardness,
toughness, ksiin
HRC
85
58-62
Tempering
temperature,F
AISI 9310
155
175
34-42
16
53
Pyrowear Alloy 53
140
170
36-44
16
67
115
59-63
300
400
225
240
48-50
16
70
130
60-62
900
199
229
48-50
18
75
85
62-64
925
JANUARY 2015
31
gearsolutions.com
Processing
Ferrium C61 and C64 steels processing
pathway permits significant reductions
in manufacturing costs and schedules.
Specifically designed to achieve high
hardenability and resist grain growth
at high temperatures, these steels take
advantage of mild-gas quenching and
high-temperature vacuum carburization
processes. This combination results in
considerable advantages (see Figure 1),
including:
1. S horter thermal processing times at
higher carburizing temperatures;
2. Reduction of quench distortion, resulting
Alloy
4340
9310
300M
S53
YS, ksi
230
155
251
226
UTS, ksi
250
175
298
288
El., %
10
16
11
15
RA, %
40
53
34
60-70
Hardness,Rc
54-60
58-62
58
54
Table 2. Ferrium S53 alloy typical property comparisons (vs. 4340, 9310, and 300M).
materials, or be reduced in size and weight
Figure 3.
by comparable amounts. C61s core UTS of Axial fatigue
240 ksi is a ~39% increase versus 9310, for
comparison
example. C64s surface hardness of 62-64 (Ferrium C61,
HRC cannot be achieved in conventional ~155 ksi, vs.
gear steels such as 9310 without sacrificing
9310, ~110
their fatigue-resistant microstructures.
ksi)
SUPERIOR HIGH
TEMPERATURE OPERABILITY
AND SURVIVABILITY SUCH
AS IN OIL-OUT EMERGENCY
CONDITIONS OR HIGHTEMPERATURE ENVIRONMENTS
The 900-925F tempering temperatures
of C61 and C64 steels are 400-600F
higher than most incumbent alloys, yielding
superior thermal stability. The combination
SINCE 1970
Anneal
Straightening
Quench & Temper
Flame Hardening
Carburize
Solution Anneal
Normalize
Shot blasting
Carbide Removal
Cryogenics
Stress Relieve
Vacuum Heat Treating
Solution Treat and Age of Aluminum/Aerospace Specifications
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205-681-8595
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33
Figure 4. Ferrium C61 prototype CH-47 Chinook helicopter forward rotor shaft manufacturing
pathway, illustrating forging (left and center) and rough machining (right).
Figure 6. One of three S53 helicopter rotor shafts for Sikorskys MH-60S (scale bar in inches)
4340
(AMS 6414)
300M
(AMS 6419)
260
280
280
285
217
230
235
240
~45*
~40*
100
100
~10
~10
~22
~88
Corrosion resistance
Poor
Poor
Marginal
Marginal
Table 3. Ferrium M54 property comparisons (vs. 4340, 300M, and AerMet100; Aerospace
Materials Specification [AMS] S-basis minimum value comparisons)
34
gearsolutions.com
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Figure 7. Ferrium M54 strain-controlled fatigue data (vs. AerMet100 data from Aerospace
Structural Metals Handbook)
transmission and gearing components
must also be upgraded. In some instances,
full power may not be achieved due to
limitations of current shafting materials
and the allowable design envelope, which
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SUMMARY
QuesTek Innovations LLC has applied
its Materials by Design computational
technology to design, develop and
implement two new high-performance
gear steels (Ferrium C61 and Ferrium
C64) and two new high-performance
structural steels (Ferrium S53 and
Ferrium M54) that are now commercially
available and can significantly reduce
rotorcraft weight and manufacturing
costs, while increasing operational
robustness (including gear steel oil-out/
high temperature survivability). QuesTek applied its ICME-based
design to the development of additional alloys that are of interest
to the gearing community.
ACKNOWLEDGMENTS
QuesTek acknowledges the support of the Department of
Defense via Army Phase II SBIR contract #W911W6-10-C-0057,
Army Phase II SBIR contract #W911W6-11-C-0053, Office of the
Secretary of Defense Phase II SBIR contract #N00014-11-C-0080,
Navy Phase II SBIR contract #N68335-11-C-0079, Navy SBIR
Phase II contract #N68335-13-C-0280, and Navy Phase
II.5 SBIR contract #N68335-11-C-0369.
REFERENCES
1. K
uehmann C., and Olson, G., Computational Materials Design
and Engineering, Materials Science and Technology, 2009, Vol.
25, No. 4, pp 472 487.
2. Wright, J., Sebastian, J., Kern, C., Kooy, R., Design, Development and
Application of New High- Performance Gear Steels, 09FTM14.
3. Kern, C., Wright, J., Sebastian, J., Grabowski, J., Jordan, D.F., and
Jones, T.M., Manufacturing and Processing of a New Class of
Vacuum-Carburized Gear Steels with Very High Hardenability,
11FTM27.
4. Wright, J., Sebastian, J., Kern, C., Kooy, R., New High-Performance
Structural Steels for Lighter, More Robust, More Economical
Rotorcraft, presented at the American Helicopter Society 67th
Annual Forum, Virginia Beach, Virginia, May 3-5, 2011.
ABOUT THE AUTHOR: Jeff Grabowski is the manager of applications development at QuesTek Innovations where he works closely with
the United States Department of Defense, the Department of Energy, and private industries to identify and address materials-related product
performance issues. QuesTek uses computational models and tools to quickly design and deploy higher-performance materials intended to
displace alloys that have been used for decades. Grabowski earned his Bachelors degree in materials science and engineering from the
University of Illinois Urbana-Champaign, and a Masters degree in materials science from Northwestern University.
38
gearsolutions.com
Allen Adams Shaper Services, Inc./Arrow Gear Company/Abundant Manufacturing, Inc. /American Gear, Inc./Artec Machine Systems/ASM International/Allied
Sinterings, Inc./Applied Process, Inc./Adams Company/American Gear Manufacturers Association/B&R Machine and Gear Corporation/Broaching Machine
Specialties/JOIN THE GROWING GEAR SOLUTIONS COMMUNITY/Balzers,
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community.gearsolutions.com
This paper discusses software that automatically generates a 3-D meshed finite
element model of a helical gear set, which does not require the gear designer to
have a knowledge of finite element analysis.
INTRODUCTION
Gears that are smaller, cheaper,
and equipped with more efficient
power transmission are the ongoing
objective of gear designers. A
significant issue in the design of
helical gears is the substantial effect
of tooth twisting under load due to
torsional and bending deflections of
the gears and associated shafts [1].
The elastic deformation experienced
in the contact area and gear body
shifts the load distribution toward one
end of the tooth, greatly increases the
maximum root stress and contact
stress, and adversely affects the
strength of the gears [2].
AGMA 927 [3] outlines an
analytical method of determining
the bending and torsional deflection
of gear shafts and the consequent
relative mesh gaps for cylindrical
gears. Finite Element Analysis (FEA)
is an alternative approach. This paper
reports the use of both approaches to
a specific gearbox. The differences
between modified and unmodified
gears are reported, as well as the
differences between the results from
the two methodologies.
A MATLAB program was developed
in this study to perform the necessary
calculations according to AGMA 927,
as well as combining gear design
processes by completing AGMA 2101
[4] power rating calculations. This
study was restricted to the analysis
of the predominant variable, namely
torsional deflection. This decision was
based on the fact that for the practical
example being analyzed, AGMA 927
HELIX ANGLE
MODIFICATION
Helix angle modification is a simple
flank modification. The modification
has the potential to significantly
reduce the load intensity and peak
stress experienced by compensation
for the torsional deflection of the gear
tooth (Figure 1).
The implementation of flank
modification also allows for a
Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria, Virginia 22314.
Statements presented in this paper are those of the authors and may not represent the position or opinion of the AMERICAN GEAR MANUFACTURERS ASSOCIATION.
JANUARY 2015
41
MATHEMATICAL
MODELLING OF TOOTH
PROFILES FOR FEA
Figure 4. Typical drive torque forces applied
to pinion nodes. Case study of an operating
gearbox
helical teeth as the contact approaches the
tip of the tooth. By reducing the loading on
the relevant side of the tooth and avoiding
end contact via helix angle modification,
the stress intensity is similarly reduced [5].
The calculations outlined in AGMA 927
facilitate the determination of the torsional
and shaft bending deflections and relative
mesh gap, and allows for a curve to be
fitted to determine the magnitude of helix
angle modification required to improve the
contact area and load distribution for a
subject gear set.
However, whilst AGMA 927 does
accommodate torsional and bending
deflections of cylinders (except for
module), it does this independent of any
tooth details (e.g. helix angle and tooth
shape). While Kissling [6] has shown the
benefits of AGMA 927 and its incorporation
into ISO 6336-1:2006 [7] with the AGMA
927 analysis being of a toothless cylinder,
there is clearly a question surrounding the
results generated by AGMA 927.
The FEA performed by the software
developed for this study allows for the
investigation of tooth shape on the
42
gearsolutions.com
(1)
FINITE ELEMENT
ANALYSIS (FEA)
In order to reduce the number of external
programs required and to streamline the
operation of the program, the geometry
was directly generated within ANSYS
Mechanical, using the native command
language ANSYS Parametric Design
Language (APDL).
The matrices of data points describing
the gears, as determined by the MATLAB
program, are used by the script to transfer
the data into the FEA program and generate
the three-dimensional models prior to FEA.
The 3-D models of the helical gears by
virtue of the robust method used to model
them, provide an accurate representation
of manufactured gears, with complex
involute profiles and helicoid contact lines.
This allows for reliable analysis of the
elastic tooth deformation to determine the
tooth contact area and load distribution via
FEA. The program automatically generates
an 8-node SOLID45 element type mesh
[13] of the gear geometry (Figure 3). The
load from the drive torque is applied evenly
to the pinion as a rotational load on each
node by the application of a tangential
load at each node using the cylindrical
coordinate system (Figure 4) akin to the
AGMA 927 method.
Figure 9. Optimization of helix angle modification for the example gear set
N, while the average station load was 2,390 N. Hence, the load
distribution factor as per Equation 38 of AGMA 927 is:
(2)
FACEWIDTH
43
MANUFACTURE AND
TESTING OF GEARS
The example gears in the case study were
manufactured in the supply of a custom
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Figure 11. Bluing of the two input pinions to check the contact area.
Figure 14. Contact area for the modified gears under the applied load.
CONCLUSIONS
45
ETC
engineeredtools.com
ACKNOWLEDGEMENTS
The authors of this paper would like to thank the AGMA
peer reviewers for their valued feedback provided in regards
to the draft of this paper, particularly their comments
regarding AGMA 927.
REFERENCES
1. Ajmi, M., and Velex, P., A model for simulating the
quasi-static and dynamic behaviour of solid wide- faced
spur and helical gears, Mechanism and Machine Theory,
vol. 40, no. 1, pp. 173-190 (2003).
2. Rao, C., and Muthuveerappan, G., Technical Note
Finite Element modelling and stress analysis of helical
gear teeth, Computers & Science, vol. 49, no. 6, pp. 10951106 (1992).
3. AGMA 927-A01, Load Distribution Factors
Analytical Methods for Cylindrical Gears (2001).
4. ANSI/AGMA 2101-D04, Fundamental Rating Factors
and Calculation Methods for Involute Spur and
Helical Gear Teeth (2004).
5. Schulze, T., Harann-Gerlach, C., and Schlecht, B.,
Calculation of Load Distribution in Planetary
Gears for an Effective Gear Design Process, AGMA
10FTM08 (2010).
6. Kissling, U., Application and Improvement of Face
Load Factor Determination Based on AGMA 927,
AGMA 13FTM08 (2013).
7. ISO 6336-1:2006, Calculation of load capacity of
spur and helical gears - Part 1: Basic principles,
introduction and general influence factors (2006).
8. Kirov, V. 2010, Comparison of the AGMA and FEA
Calculations of Gears and Gearbox Components
Applied in the Environment of Small Gear Company,
AGMA 10FTM05, (2010).
9. AS 2938-1993, Gears Spur and helical Guide to
specification and rating (1993).
10. ISO 53:1998, Cylindrical gears for general and
heavy engineering Standard basic rack tooth profile
(1998).
11. Wilkinson, T.B., A computer program to produce
plots of gear tooth profiles and meshing, Undergraduate
thesis, University of Wollongong, Wollongong, NSW(
1981).
12. Hedlund, J., and Lehtovaara, A., Modeling of
helical gear contact with tooth deflection, Tribology
International, vol. 40, pp. 613-619 (2006).
13. Rameshkumar, M., Venkatesan, G., and Sivakumar,
P., Finite Element Analysis of High Contact Ratio Gear,
AGMA 10FTM06 (2010).
14. Davey, R.J. & Fay, L., PHD Engineering Pty Ltd,
Internal Reports - Private Correspondence, 1999.
15. Hipsley, S.R., Optimisation of Gear Tooth Contact
by Helix Angle Modification, Undergraduate Thesis,
Department of Mechanical Engineering, University of
Wollongong, Australia (2013).
ABOUT THE AUTHOR: S tuart Hipsley is currently a mechanical engineer working for PHD Engineering Pty Ltd (PHD), a consulting practice,
operating in Wollongong, Australia. PHD specializes in the design of custom-made gearboxes and specialized uprating of mechanical
equipment. He recently earned his Bachelor degree in mechanical engineering at the University of Wollongong with first class honors, which
included an undergraduate thesis.
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INDEX
COMPANYNAME
PAGE NO.
.25 to 34 Diameter
32 DP to 1.5 DP
GEARS
.5 Module to 16 Module
SPIRAL
BEVEL GEARS
.25 to 33 Diameter
32 DP to 2 DP
.5 Module to 12 Module
JANUARY 2015
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Q&A
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