GEAR SOLUTIONS MAGAZINE

EXTENDING GEAR LIFE IN DEMANDING APPLICATIONS

Extending Gear Life in

Demanding Applications
ISSUE FOCUS
Raw Materials
Coating/Finishing

COMPANY PROFILE:
Bevel Gears (India) Pvt. Ltd.
JANUARY 2018

JANUARY 2018
Your Resource for Machines, Services, and Tooling for the Gear Industry gearsolutions.com
 Achieving Increased Profits and Response Times
with Modular Vacuum, Atmosphere Furnaces

“Initially, what appealed to us about this Ipsen

equipment was its general purposefulness ... We
wanted a low-cost, off-the-shelf-type solution that
would allow us the flexibility we required – which
is what the ATLAS and TITAN ® delivered. Now
after having performed some pre-training, I would
say what stands out the most for both are the
ease of use and control of the equipment.”
– Continuous Improvement Manager

Customer Story

As a leading global technology provider, this
customer decided to move their existing facility to
a new location so they could continue to grow and
advance. As such, any new equipment they chose
needed to be able to handle the everyday range of
requests, from different processes and part
geometries to different load sizes.
After much consideration, it was Ipsen’s ability to
provide modular platforms for both vacuum and
atmosphere furnaces in the form of the TITAN®
and ATLAS, as well as the necessary training and
support, that interested them.
From supervising the installation to providing
operator training, the Ipsen Field Service
Engineers took the pressure off the customer and
had the equipment up and running in no time. The
customer also took advantage of Ipsen U, a
three-day training that gave them a deeper
understanding of how to effectively operate and
maintain their new investments. They have also
started to notice some of the advantages the
atmosphere furnaces provide, including …

Discover this customer’s winning outcome:

www.IpsenUSA.com go.IpsenUSA.com/Customer-Stories

www.IpsenUSA.com
Whatever your needs, we’ve got you covered!
We’re all g-EARS

www.toolink-eng.com

303-776-6212
 Perfect Fit

Whether you need PM-HSS, G90 or carbide tools, we have the

right solution to fit your application. All available with advanced PVD
coatings for greater performance in all types of cutting conditions.

www.gleason.com/fit

© Gleason Corporation. All rights reserved.

 FEATURES

Bevel Gears (India) Pvt. Ltd.

26
By Kenneth Carter
Bevel Gears (India) Pvt. Ltd. has designed and manufactured bevel gears
and bevel gearboxes for more than 40 years

Fatigue Performance and Cleanliness

30 of Carburizing Steels for Gears
By Joakim Fagerlund, MSc, and Lily Kamjou, MSc
This investigation shows that steels with a higher cleanliness level reach a higher performance level
as well, both in terms of increased loads and longer service life.

Advanced Thermal Processing for Enhanced Gear Tribology

38 By Boris Zhmud, Johan Blomkvist, and Mikael Fallström
TriboNite technology can help improve gear performance by combining the well-known advantages
of nitriding with the superior tribological performance profile of solid lubricant coatings.

Extending gear life in demanding applications

42 By Jeff Elliott
Specialized PVD coatings increase the surface hardness and durability of gears, thereby increasing
their lifespan under high-load conditions.

Closed Loop Machining of Cylindrical Gears

46 By Dr. Markus Brumm
Looking to raise the quality and accuracy of your gearing? Consider Closed Loop design and
manufacturing, which has done away with the error-prone data transfer from the measuring sheet.

JANUARY  2018 3
Manufacturers of:

and Universal Gear Company

1605 Industrial Drive
Auburn, CA 95603
Phone: (530) 885-1939
Fax: (530) 885-8157
 DEPARTMENTS
08


INDUSTRY
NEWS
Reports, data, and developments to keep
you aware of what’s happening with your
colleagues in the gear-manufacturing
industry around the country and world.
CMS announces call for papers Kollmorgen sets demos for IPPE 2018

15 American
In this section, the premier supporter of gear manufacturing in the United States
and beyond shares news of the organization’s activities, upcoming educational and
training opportunities, technical meetings and seminars, standards development,
Gear Manufacturers
and the actions of AGMA councils and committees. Association

20 MATERIALS 50
PRODUCT 56 Q&A
MATTER SHOWCASE
Will Terry
Mike Burnett
PRODUCT MANAGER
MACHINABILITY AND THE COST OF MANUFACTURING GEARS
OF SPECIAL PURPOSE MACHINES
Taking material modifications into consideration can play an
JTEKT Toyoda Americas Corporation
important role in reducing overall machining costs. Here are
some helpful tips.

22


TOOTH
TIPS
Brian Dengel
MAKING THE BEST SELECTION
There are different types of gears to choose from depending
on the orientation of the application.

24

HOT
SEAT
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,
D. Scott MacKenzie, Ph.D., FASM Richmond Hill, ON L4B4R6. Copyright®© 2006 by Media Solutions, Inc. All rights reserved.
OIL QUENCHANTS UNDERSTANDING
THE CHEMISTRY (PART I) 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
This installment explores the chemistry of oil quenchants permission in writing from the publisher. The views expressed by those not on the staff on Gear Solutions
and the effects of additive packages on quenching 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
performance, to be followed in February by a discussion site, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted
of base oils. to editor@gearsolutions.com.

JANUARY 2018
VOLUME 16 / NO. 1
Cover Courtesy: Oerlikon

JANUARY  2018 5
 EDITOR'S
LETTER David C. Cooper
PUBLISHER
Chad Morrison
ASSOCIATE PUBLISHER

2018: A year for gears EDITORIAL

All indications are that 2018 is going to be a great year for the gear manufacturing industry.
Kenneth Carter
EDITOR
And with that, Gear Solutions will continue to bring you the information for, about, and
from the gear industry to help you take your business above and beyond for not only this
Russ Willcutt
CONTRIBUTING EDITOR
year, but years to come.
During the year, Gear Solutions is going to soon launch a newly redesigned website that Jennifer Jacobson
ASSOCIATE EDITOR
will allow you to search our database with ease. The new site has an intuitive interface and
a dynamic new look that will surely keep you coming back for more.
2018 also marks a special year for Gear Solutions, as we will celebrate 15 years of bringing SALES
you hundreds of highly researched articles from some of the brightest minds in the industry. Chad Morrison
In addition to our new online look coming soon, we also are going to be exploring ways ASSOCIATE PUBLISHER
to make our print magazine even more enticing with a design that will make you take notice Dave Gomez
and content that will keep you turning those pages from cover to cover. REGIONAL SALES MANAGER
You’ll find a lot of those types of articles in our January issue as we focus on raw materials
and coating/finishing.
Starting off our Focus section is an AGMA paper on the “Fatigue Performance and CIRCULATION
Cleanliness of Carburizing Steels for Gears.” Teresa Cooper
MANAGER
We also have an interesting article on “Advanced Thermal Processing and Coating Process
for Enhancing Gear Tribology.” Jamie Willett
ASSISTANT
Our contributing columnists are ringing in the new year with subjects ranging from how
to make the best selection when it comes to different types of gears, to understanding the Cole Morrison
chemistry of oil quenchants, to machinability and the cost of manufacturing gears. ASSISTANT
In our Q&A feature, we introduce our readers to Will Terry, Toyoda product manager of
Special Purpose Machines. This is the first time Toyoda has participated with Gear Solutions, ART
and I suspect it won’t be the last as the company is eager to share more of what it does for Shane Bell
the gear industry with the rest of the world. CREATIVE DIRECTOR
So take a look at what we’re offering this month and just know there’s more where that
Michele Hall
came from in the coming year. GRAPHIC DESIGNER
And as always, thanks for reading!

CONTRIBUTING
WRITERS
JOAKIM FAGERLUND
LILY KAMJOU
BORIS ZHMUD
JOHAN BLOMKVIST
MIKAEL FALLSTROM
MARKUS BRUMM
Kenneth Carter D. SCOTT MACKENZIE
Editor MIKE BURNETT
Gear Solutions magazine BRIAN DENGEL
editor@gearsolutions.com MATT CROSON
JEFF ELLIOTT
(800) 366-2185 x204

PUBLISHED BY MEDIA SOLUTIONS, INC.

P. O. BOX 1987 • PELHAM, AL 35124
(800) 366-2185 • (205) 380-1580 FAX
David C. Cooper Chad Morrison
PRESIDENT VICE PRESIDENT
Teresa Cooper
OPERATIONS

6 gearsolutions.com
 FELLOWS 20-8 GEAR SHAPERS
HYDROSTROKE SHAPERS • REMANUFACTURED IN 2017

Y ea h , w e ’v e got t h at!

We have the world’s largest stock

of used late-model Fellows Gear Shapers.
WE OWN WHAT WE SELL, AND WE KNOW WHAT WE’RE SELLING!

REMANUFACTURED
RETROFITTING
CUSTOM MACHINES
860-223-7778
www.NewEnglandGear.com

343 JOHN DOWNEY DRIVE • NEW BRITAIN, CT 06051-2907 • PHONE 860-223-7778 • FAX 860-223-7776 • JEFF@NEWENGLANDGEAR.COM
 INDUSTRY NEW TRENDS, SERVICES,

NEWS AND DEVELOPMENTS

Forest City Gear earns certification

Forest City Gear has successfully met the
Women’s Business Enterprise National
Council’s standards for certification as a
Women’s Business Enterprise.
WBENC National WBE Certification
validates that the business is owned, con-
trolled, operated, and managed by a woman
or women. To achieve WBE Certification,
women-owned businesses complete a rigorous
documentation and site visit process. WBE
Certification is an important accreditation
recognized by hundreds of WBENC cor-
porate members and government agencies,
including most major U.S. corporations and
federal, state, and local government entities.
“Supplier diversity is an increasingly
important aspect of the procurement pro-
cess that Forest City Gear is involved with
in the industries we serve, and the WBE
Certification gives us critical recognition,”
said Forest City Gear President and CEO
Wendy Young.
Since 1955, Roscoe, Illinois-based, family-
owned Forest City Gear has been one of
the gear industry’s leading sources for the
development, manufacture, and inspection of
the highest quality gears for use in applica-
tions including medical devices, motorcycles,
airplanes, automation, and even the Mars
Curiosity Rover.

FOR MORE INFORMATION: forestcitygear.com

CMS announces call for papers

The Coordinate Metrology Society’s (CMS)
34th annual Coordinate Metrology Society
Conference (CMSC) will be July 23-27,
2018, in Reno, Nevada, and the group has
issued a call for papers. The CMS is the
eminent membership association for mea-
surement professionals worldwide. For the
first time, the organization is opening its call
for papers to the Coordinate Measurement
Machine (CMM) community, in addition
to its portable measurement systems soci-
ety. The CMS encourages abstract submis-
sions that explore diverse applications of 3D
metrology to improve processes, productiv-
ity, and the user experience. Since 1984,
industry leaders have contributed more
than 500 high-level technical papers and
presentations to the CMSC portfolio, the
most comprehensive repository of metrology
knowledge and information.
The Coordinate Metrology Society encour-
ages papers and presentations that cover
research and development driving the future After the conference, the CMS Executive Committee will select the top technical papers presented at CMSC 2018 for
of metrology such as the Smart Factory, 3D publication in the prestigious Journal of the CMSC. (Courtesy: CMSC)
printing, artificial intelligence (AI), auto- can cover all aspects of metrology competen- The deadline for abstract submissions for
mation and manufacturing cells, and other cies gained from research and development, technical papers and presentations is March
trends that unlock the potential of 3D metrol- best practices, technology benchmarks, and 9, 2018. The CMS Executive Committee
ogy technologies. Submissions must be origi- innovative use cases exploring the adoption peer reviews each abstract and, if selected,
nal, expert-level contributions from metrol- or adaption of metrology solutions for prob- the speaker will receive a Notification of
ogy practitioners working in the portable lem solving or process control. Commercial Acceptance on April 6, 2018. As a bonus,
and CMM metrology field. Technical papers content is not accepted by the CMS. conference registration and membership fees

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

8 gearsolutions.com
are waived for individual speakers presenting at
the conference. In the case of multiple authors,
the CMS will waive one conference registra-
tion and membership fee. Contact Daniel
Sawyer, Scott Sandwith, or Michelle Edwards,
Technical Presentations Coordinators, at pre-
sentations@cmsc.org for more information.
After the conference, the CMS Executive
Committee will select the top technical papers
presented at CMSC 2018 for publication in
the prestigious Journal of the CMSC. The
technical journal provides additional coverage
of the published work to an even larger global
audience. CMS members in good standing
can also access the technical papers and pre-
sentations via the CMSC website. Authors
and researchers are also encouraged to cite
CMSC technical papers if referenced in their
own technical papers.
The Coordinate Metrology Society dedi-
cates itself to serving the education and
career needs of expert and novice metrolo-
gists. An impressive array of authoritative
white papers and presentations were deliv-
ered at its 2017 conference, covering topics
from close-range photogrammetry in space
to metrology-guided wing join automation
to point cloud measurements on a CMM
artifact using a laser scanner. Speakers
hailed from NASA (Johnson Space Center),
Triumph Aerostructures (Vought Aircraft
Division), IK4-TEKNIKER (Spain), Idaho
Virtualization Laboratory, Lawrence Berkeley
National Laboratory, Brookhaven National
Laboratory, National Institute for Standards
and Technology (NIST), National Physical
Laboratory (NPL- UK), Los Alamos National
Laboratory, Argonne National Laboratory,
UNC Charlotte, University College London,
Academy of Opto-electronics, Chinese
Academy of Sciences, Tianjin University, and
other leaders in the field.

FOR MORE INFORMATION: CMSC.org

Sandvik announces 2018 training schedule

2018 is right around the corner, and it's time
to prepare for the upcoming year. Mark your
calendars for one of Sandvik’s many technical
training offerings and keep an eye out for
registration links.
The Sandvik technical training courses
are intended to educate production manag-
ers, engineers, and machine operators on the
most up-to-date techniques in metal cutting.
Educating the workforce is key to maintain-
ing a competitive edge while also optimiz-
ing work processes. This investment in staff
members’ metal-cutting skills can make a
significant difference when measuring a com-
pany's productivity.
Many of the three-day courses range from
basic application of tools to higher-level train-
ing specializing in advanced topics. 
Trainings are conducted at
Sandvik’s  Productivity Centers around the
country, offering hands-on learning from
its skilled experts. The centers are equipped
with state-of-the-art machines for live dem-
onstrations including milling, turning, and
hole making. 

FOR MORE INFORMATION: sandvik.coromant.com

Third Wave Systems sets conferences

Third Wave Systems is gearing up for the Fachhochschule Köln that will feature a tour Conference, featuring some of our most
2018 Users Conferences and already has of its laboratory and engineering facility, as popular speakers from the last few years
a lineup of speakers to be excited about. well as food and drinks (there might even be a who will give updates on their research
Stay tuned for more presenters and Users robot that will open and pour a beer for you)! and machining processes and modeling
Conference updates regarding workshops, Attendees will hear from: technology advancements.
networking events and more. • FMT Tooling. Attendees will also have the chance to
• Fraunhofer IPA. participate in an all-access event at the Rock
Cologne, Germany • ISBE GmbH. & Roll Hall of Fame.
The 2018 European Users Conference will • iWFT and more. Attendees will hear from:
return to Germany February 26-28 to host • General Motors.
presenters who are experts in modeling tech- Cleveland, Ohio • National Institute of Standards and
nology and two networking events including Join Third Wave in Cleveland May Technology (NIST).
a welcome reception at iWFT Rheinische 15-17, 2018, for the International Users • University of Wisconsin-Madison and more.

FOR MORE INFORMATION: thirdwavesys.com

Kollmorgen sets demos for IPPE 2018

Kollmorgen will feature newly launched prod- International Production & Processing Expo Throughout the show, Kollmorgen will
ucts, live demos, and the latest research on (IPPE), January 30 – February 1, 2018, at the demonstrate its AK MHTM Hygienic
hygienic machine design at Booth C1105 at the Georgia World Congress Center in Atlanta. Servo Motor. Recognized for exceptional
JANUARY  2018 9
reliability, the AKMH is designed to with-
stand the most rigorous washdown environ-
ments for higher overall equipment effective-
ness (OEE). Lower total cost of ownership
(TCO) is achieved through reduced cleaning
time and increased uptime; the risk of food
recall is significantly reduced by the motor’s
superior hygienic design.
Kollmorgen will also introduce the new
AKM®2G synchronous servo motor, the next
generation of its industry-leading AKM®
motor product family. The higher-torque
density of the AKM2G allows OEMs to
substantially increase machine performance
without increasing motor size. With average
continuous torque increases of 30 percent,
space dedicated to motors and mechanical
components can be significantly reduced.
Attendees are invited to experience
Kollmorgen’s wash-down tank demo, a first
at IPPE. The demo incorporates the new
AKM2G, AKD®-N de-centralized drive,
AKMH hygienic servo motor, and AquaTrue®
hygienic gearboxes to show how the compo-
nents work together to create a total hygienic
solution that increases reliability while reduc-
ing cleaning time and the risk of food recall.
“We have many exciting things to share
at IPPE this year. We’ll be talking about the
AKMH’s unrivaled reliability and the advantages
it offers OEMs,” said Bill Sutton, market devel-
opment manager at Kollmorgen. “We’re also
excited about the AKM2G, the newest mem-
FOR MORE INFORMATION: kollmorgen.com
Motion Canada’s TechCan Services earns two SKF certifications
Motion Industries, Inc., a leading distributor
of maintenance, repair, and operation replace-
ment parts and a wholly owned subsidiary of
Genuine Parts Company, recently announced
that its Motion Canada TechCan Services in
Edmonton, Alberta, has been authorized as
an SKF Certified Rebuilder — Gearboxes,
as well as an SKF Certified Rebuilder —
Conveyor Pulleys.
SKF associates audited TechCan Services
and presented certification signifying that
TechCan had met all the necessary crite-
ria, with the emphasis on teardown and
inspection procedures, machine tools and
repair procedures, storage, documentation,
and other exacting standards and technical
specifications. Before the final audit, SKF
held training for the shop and helped develop
action items in order to assist TechCan in
reaching certification levels and becoming a
10 gearsolutions.com
The AKM2G, the newest member of Kollmorgen’s AKM motor family, has improved torque density which allows OEMs
to use a smaller motor to reduce the machine footprint without sacrificing performance. (Courtesy: Kollmorgen)
ber of our AKM motor family. The improved
torque density allows OEMs to use a smaller
motor to reduce the machine footprint without
sacrificing performance. And AKM2G deployed
into existing OEM designs will enable increased
throughput and additional product capacity.”
In addition to learning about new products
and hygienic design solutions, IPPE attend-
ees are invited to visit booth C1105 to dis-
cuss their specific application needs with a
Kollmorgen expert. Advance meetings can
be scheduled by contacting Bill Sutton at
Bill.Sutton@Kollmorgen.com.
best-in-class service provider.
Shawn Gibson, president of SKF Canada,
said, “Customers are asking us to increase
uptime and to provide solutions that lower
total cost of ownership. We recognize custom-
ers want their equipment to operate trouble-
free. SKF Certified rebuilder program pro-
vides the right processes, training, tools, and
components to achieve cost-effective re-builds
and often upgrading to better than new.
I am very impressed by TechCan Services’
commitment and its diligent work and profes-
sionalism in obtaining its certifications. We
will support TechCan Services with applica-
tion engineering and gearbox remanufactur-
ing from our Industrial service center in
Cambridge, Ontario.”
SKF’s Certified Rebuilder programs are
designed to keep authorized service centers
up-to-date with the latest technologies and
Since its founding in 1916, Kollmorgen’s
innovative solutions have brought big ideas
to life, kept the world safer, and improved
peoples’ lives. Today, its world-class knowledge
of motion systems and components, industry-
leading quality, and deep expertise in linking
and integrating standard and custom prod-
ucts continually delivers breakthrough motion
solutions that are unmatched in performance,
reliability, and ease-of-use. This gives machine
builders around the world an irrefutable mar-
ketplace advantage and provides their custom-
ers with ultimate peace-of-mind.
best practices. SKF Certified Rebuilders
must complete regular audits to help ensure
compliance with SKF’s rigorous standards,
and must also meet their requirements for
continuous improvement and competence
development.
Mark Tinis, TechCan branch manager,
said, “Being a qualified, certified SKF partner
allows us to communicate to our customers
that we hold ourselves to those same, very
high standards. It’s very important to our
customers that they can send their compo-
nents in to a service center and not have to
worry about it. They can have 100 percent
confidence the rebuilds will be completed
right the first time and every time.”
Brent Pope, vice president general man-
ager of Motion Industries Canada, said,
“I would like to thank TechCan manager
Mark Tinis for his leadership in achieving
these certifications, and we are very proud of customer to achieve both certifications for one Canada an advantage in the marketplace.”
the fact that Motion Industries is the first SKF facility. They will provide Motion Industries SKF is one of Motion Industries’ key suppliers.

FOR MORE INFORMATION: motionindustries.com

Niigata announces new North American headquarters

in long-term customer satisfaction and loy-
alty,” said Hans Retra, president and CEO
of Niigata Machine Techno USA, Inc. “The
first Niigata machine sells the next.”
The wide range of models includes heavy-
duty boxway, roller guide, and hybrid (box-
way and roller guide) machines, with work
envelopes reaching 1,600 mm. For versatile
machining, Niigata also offers a line of facing
centers and bar machines.

Centrally located in the Midwest, the headquarters

The
supports North American manufacturing with a full
line of Niigata horizontal machining centers and parts.
(Courtesy: Niigata)

Niigata, a world leader in horizontal machin-

ing centers, recently announced the opening Power
of One2
of its North American headquarters, Niigata
Machine Techno USA, Inc., in Elk Grove
Village, Illinois.
Already well established in the U.S. since
1980, Niigata’s expansion further reinforces Your Objective:
its commitment to the market. Centrally One face in perfect alignment with another. For infinity.
located in the Midwest, the headquarters sup-
ports North American manufacturing with a
full line of Niigata horizontal machining cen-
ters and parts. The new facility also provides
expert service, applications engineering, and
technical support.
Recognized worldwide for its reliable, high-
quality, and innovative horizontal machining
centers, the machine tool builder was founded
in 1895 in Japan. A wholly owned subsid-
No problems. No distress. No delays.
iary of Niigata Machine Techno Co., Ltd in That’s the same objective you have for choosing your gear producer.
Circle Gear’s objective is to engage with every customer’s objectives.
Niigata City, Japan, the new U.S. location
is the exclusive North American distributor  One to 1000 gears
of the Niigata product line. As horizontal
 Customer designed or reverse engineered
machining center specialists, Niigata world-
class solutions feature high-speed, accurate,  Gearbox repair, rebuild or redesign
and productive performance. “Our long tra-  OEM or end-users
dition of exceeding expectations has resulted  ISO 9001:2015 Certified
FOR MORE INFORMATION: niigatausa.com
1501 S. 55th Court, Cicero, IL 60804
(800) 637-9335
(708) 652-1000 / Fax: (708) 652-1100

New Seco ceramic inserts, sales@circlegear.com

cutter bodies maximize
HRSA machining
Seco Tools now offers Secomax™ CS300 ceram-
ic inserts and cutter bodies to boost productivity
in milling and turning operations with heavy
interrupted cuts on nickel-based heat-resistant
www.circlegear.com
Spiral and Straight Bevel Gears (Cut, Ground or Lapped) • Spur Gears • Helical Gears •
Long Shafts • Herringbone Gears • Involute and Straight Sided Splines • Internal Gears •
Worm and Worm Gears • Racks • Sprockets • ISO Certified
Partnering with QualityReducer to provide
Gearbox repair, rebuilding and reverse-engineering.
JANUARY  2018 11
superalloys (HRSA). The new cutters increase
productivity by up to eight times over standard
carbide milling and are ideal for machining a
wide range of components for aerospace and
power generation turbine segments.
CS300 inserts are SiAlON-type ceramics
that offer high notch wear resistance, toughness,
and thermal shock resistance. The inserts pro-
vide optimum flank wear resistance at higher
cutting speeds ranging from 1,970 – 3,940 feet
(600 – 1,200 meters) per minute and enable
feeds from 0.002 – 0.006 inches (0.05 – 0.15
mm) per tooth. Combined, these attributes
reduce machining cost per workpiece, increase
output, and lower energy consumption.
The new R220.26 and R217.26 cutter bod-
ies are hardened and nickel-coated for high
reliability, reduced chip friction, and bet-
ter resistance to high temperatures. Wedge
clamps provide more secure insert locking,
and feature internal air coolant channels that
ensure optimum chip evacuation and heat
control. The metric range includes cutter
bodies with RP 1204 inserts for facing and
pocketing in diameters from 32 to 50 mm.
Cutters with RN 1207 and RN 1204 inserts
for facing are available in diameters from Seco Tools CS300 ceramic inserts are SiAlON-type
32 to 125 mm. The imperial range includes ceramics that offer high notch wear resistance, toughness,
diameters 2.0", 2.5" and 3.0". and thermal shock resistance. (Courtesy: Seco Tools)

FOR MORE INFORMATION: secotools.com

Hand tool manufacturer boosts production with compact tempering system

Seco/Warwick has partnered with a tool manu-
facturer in North America to custom design a
pit-type tempering furnace system to increase
production capacity. This system will be used
for heat-treating power tool components and
was specifically designed to fit into a limited
footprint within the existing facility layout.
“At Seco/Warwick, we understand that ‘one
size fits all’ does not apply in the industrial
environment,” said Jonathan Markley, managing
director, Seco/Warwick, USA. “We understand
that customers often have to increase production
capacity, but do not have the luxury of increasing
their physical plant production area. Designing
for efficient production requires technical exper-
tise to ensure that we get our customer’s equip-
ment online and performing beyond expectations
in the shortest possible time.”
Seco/Warwick’s atmosphere heat-treating
equipment is used both with and without pro-
tective atmospheres in a wide range of configu-
rations for most heat treatments in use by tool
manufacturers.
Pit furnaces have the long track record for
practical, economical heat-treating. In addi-
tion, Seco/Warwick offers material handling
equipment, cooling systems, and protective
atmosphere systems to create a complete manu-
facturing cell with both batch and continuous
system options.

FOR MORE INFORMATION: secowarwick.com

Aerospace supplier
collaborates with Fives
to advance titanium cutting
Acromil Corporation, a primary supplier of
complex structural components and assem-
blies to the aerospace and defense indus-
tries, has ordered two advanced Cincinnati
Wide-Range (WR)Titanium Profilers and a
Giddings & Lewis Horizontal Boring Mill
(HBM) from Fives as the start of a two-
phase expansion. Acromil and Fives will
also collaborate to establish a world-class
hard metals manufacturing center with the
latest 5-Axis high metal removal technology,
with a goal of developing the most produc-
tive titanium cutting machines available.
The new Cincinnati WR profiler version is
optimized for difficult to machine materials,
Fives Cincinnati (Courtesy: Fives)
such as titanium and stainless steel.
“Our expansion demonstrates a commit- to be a Tier 1 supplier supporting customer dent. “We believe our collaboration with Fives
ment to the defense and aerospace industries, needs for detail parts and assemblies,” said Group will change the way aerospace manu-
with the primary goal of developing Acromil Ed Hatcher, Acromil’s executive vice presi- facturers approach titanium machining.”
12 gearsolutions.com
 The Cincinnati WR Titanium Profilers
are designed, manufactured, and delivered by
Fives Cincinnati, Hebron, Kentucky, while
the Giddings & Lewis HBM is produced and
shipped from Fives Giddings & Lewis in Fond
du Lac, Wisconsin.
“The new profilers have been tested exten-
sively with excellent results,” said Steve
Thiry, president and general manager of
Fives Machining Systems Inc. “The HBM
will handle titanium structural components
(for a major aerospace OEM) that will high-
light the versatility of the Giddings & Lewis
FOR MORE INFORMATION: fivesgroup.com
TWS’ AdvantEdge v7.4 now available
AdvantEdge v7.4 is now available from
Third Wave Systems. The release includes
time history data averaging, report
improvements, milling Boolean robustness
enhancements, job monitor improvements,
and bug fixes.
With users running larger and larger design
of experiment simulation sets, data extraction
has become more important. The time his-
tory data averaging feature enables users to
quickly and reliably collect data from a large
number of simulations for all time history
FOR MORE INFORMATION: www.thirdwavesys.com
New GF Machining high-speed mill adds flexibility to graphite machine
To meet the extremely demanding mold and
die machining needs of high-tech industries,
GF Machining Solutions has unveiled the
new Mikron HSM 500 Graphite high-speed
mill. The system combines the features of a
dedicated graphite machine with the flex-
ibility of the company’s HSM 500 high-
speed milling platform. Clad in black paint
to denote its specialty, the machine sports
an optimized Step-Tec 42,000-rpm spindle,
a sophisticated exhaust system, and the abil-
ity to quickly switch between wet and dry
machining.
The flexibility of the HSM 500 Graphite
ensures that shops can have an all-in-one high-
speed milling solution that allows for wet
applications while at the same time benefiting
from a machine that specializes in graphite
applications. Its high-dynamic drives, polymer
concrete base, and improved spindle allow the
machine to hold extremely tight tolerances,
machines. It’s also a great opportunity for
us to work with industry veterans like Ed
Hatcher from Acromil.”
Within Fives, Metal Cutting | Composites
business line, is comprised of Fives
Machining Systems Inc., which includes
Fives Cincinnati in Hebron, Kentucky,
specializing in machines and systems for
the aerospace and industrial sectors and
Fives Giddings & Lewis in Fond du Lac,
Wisconsin, specializing in machine tools for
the industrial, aerospace, and automotive
sectors; Fives Lund Engineering in Seattle,
results (temperature, forces, power, torque,
etc.). The data is then displayed in Tecplot
and can be exported as a .csv file for further
post-processing.
The success of the results analysis wiz-
ard and automated report has resulted in
requests for including non-simulation data.
In response, TWS has developed enhance-
ments for adding custom sections to include
experimental or third-party analysis results,
the functionality to import images, and the
ability to sort/rename captured images.
such as those required for advanced glass molds
and other graphite parts.
“For most applications, the entire process
has to be perfect, not just the machine,”
said Dante Payva, project manager of GF
Machining Solutions’ milling division.
“Everything needs to be considered, from the
overall shop environment and temperature to
the precise measurement of the cutters and
process speeds. Our smart machine mod-
ules and training programs make that easier
than ever even as our machines become more
sophisticated.”
To that end, the HSM 500 Graphite
includes the operator support system for auto-
mating complex machine setting changes,
intelligent thermal control for warm-up time
reductions as well as the highest possible
accuracy, and an advanced process system
for on-the-fly control of spindle functions.
GF Machining Solutions has also designed
serving the aerospace industry; Fives Liné
Machines in Granby, Quebec, Canada,
and Fives Machining in France, specializ-
ing in machine tools for aerospace, indus-
trial, and rail sectors. The Metal Cutting
| Composites teams also operate Global
Aftermarket Machine Services, with more
than 20 service centers worldwide, includ-
ing seven in North America in Hebron,
Kentucky; Seattle, Washington; Valencia,
California; Wichita, Kansas; Charlotte,
North Carolina; Fond du Lac, Wisconsin;
and Cambridge, Ontario.
Additional improvements to the software
focused on milling Boolean robustness, the
job monitor and minor bug fixes. Milling
Boolean robustness for small feed cases with
large axial depth of cut and/or large radial
depth of cut was significantly improved and
resulted in better workpiece accuracy for
all milling processes. The job monitor now
allows a user to append or rebuild the job
list when moving to a new computer or the
job list is unexpectedly deleted and needs to
be recreated.
The system combines the features of a dedicated
graphite machine with the flexibility of the company’s
HSM 500 high-speed milling platform.
(Courtesy: GF Machining)
JANUARY  2018 13
the machine around its automation and die- such machines as a System 3R WorkPartner highest level of precision at speeds that allow
sinking EDM lines to provide customers with 1+ and an AgieCharmilles FORM P 250. for doubled production capacity and up to
a complete manufacturing solution, making The result of these innovations is a machine 200 percent more profit when compared to
it easy to pair the HSM 500 Graphite with that can reliably and repeatedly provide the competing graphite mills.

FOR MORE INFORMATION: www.gfms.com

Hexagon expands flagship Leica Absolute Scanner range

Hexagon Manufacturing Intelligence, the Absolute Scanner LAS-XL, a new ultra-large
leading metrology and manufacturing solu- scale portable laser scanner. Designed for
tion specialist, recently announced the Leica industries and applications where both speed

Why ETC? The new Leica Absolute Scanner LAS-XL defines a new
market segment with a larger scanning field than any
other laser scanner. (Courtesy: Hexagon Manufacturing
Intelligence)

of measurement and metrology-level accuracy

are indispensable, the expanded measurement
field and point acquisition rate of the LAS-XL
NEW and RECONDITIONED
CUTTER BODIES for Sale.
means large parts and surfaces can be fully
digitized in far less time than before.
Operating on the same flying-dot scan-
ning technology as the Leica Absolute
Scanner LAS, the LAS-XL benefits from
a scan-line width of up to 600 millimeters
(24 inches) and a measurement stand-off
distance of up to a full meter. The extreme
flexibility this delivers makes the LAS-XL
as ideal for mapping large blade surfaces as
it is for digitizing aircraft and rail carriage
interiors. Accurate to within 150 microns,
the LAS-XL is suitable for the wide range
of applications for which increased measure-
ment speed is extremely valuable.
“What we’re seeing with our customers
is that there is a huge range of applications
Customer Service, Speed, Quality, & Value out there for which much improved speed of
measurement is more critical than unbeat-
able accuracy,” said Daniel Moser, technical

ETC
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Engineered Tools Corporation
Complete line of Bevel Gear Tooling
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product director at Hexagon Manufacturing
Intelligence. “The LAS-XL is our attempt
to meet the needs of this part of the market
that has until now been under-served by
the metrology industry. Absolute accuracy
is a key part of our product philosophy, but
sometimes really great accuracy done really
quickly is the better solution.”
The LAS-XL is compatible with all Leica
Absolute Tracker AT960 models and is avail-
able to order worldwide. 

engineeredtools.com FOR MORE INFORMATION:

www.hexagonmi.com
14 gearsolutions.com
 American Jenny Blackford

Gear Manufacturers Vice President

Matthew Croson
Communications
AGMA
of
President
Association AGMA

INNOVATORS WANTED:
AGMA’s direction focused on value creation
AGMA’s strategic plan is not sitting on a bookshelf collecting dust. In the past year, we connected hundreds of professionals together
It hasn’t been placed in the bottom of the filing cabinet, or checked at global events such as Hannover Messe.
off as “done” after the vote took place in November 2016. In the past year, AGMA has produced two new classes to expand
AGMA’s strategic plan is a living, breathing document — re-ener- our program to offer more opportunities.
gizing our 102-year-old association by focusing on critical business We have expanded communications to include a presence on the major
challenges and opportunities facing the industry today. social media platforms including Twitter, LinkedIn, Facebook, and with
AGMA defined a global opportunity where AGMA is present a new blog called Gears Matter.
in countries that are significant opportunities. In 2018, this means The vision for AGMA is that AGMA and its members drive power
AGMA will hold its first-ever Steels for Gears class in Mumbai, India, transmission innovation.
in February. It also means we will take 20-plus members to China on I have demonstrated examples of how AGMA is supporting this
a trade mission to understand our supply chain in October. vision with new and innovative approaches. There is a lot to do yet,
AGMA defined an emerging technology opportunity whereby the and 2018 is the year to make it work.
Association focuses time and energy on disruptive technologies that are What we need now is our innovators who want to collaborate with
both challenges and opportunities. In 2018, this means AGMA will us and keep this momentum going. That is why you will start to see
feature a robotics panel at the Annual Meeting; we will collaborate with some marketing and communications focused on the “Innovators
DMDII to address additive manufacturing capabilities, and we will Wanted” framework. Let us know where you want to jump in to
bring subject matter experts to other events in order to ensure members focus on one simple but important thing: Innovation!
are aware of what will be affecting them in the coming months. Here is what AGMA is planning to do:
AGMA defined an industry voice opportunity where we can • We are putting members in front of industry leaders and subject
partner with new and different groups to expand the leading Power matter experts on a global level. We want members to learn from
Transmission Trade Show in the U.S. to include mechanical, elec- the best, so they can innovate anywhere in the world.
trical, and fluid power solutions sets, which all customers need to • We are jumping into the middle of complicated emerging technolo-
consider in order to innovate their power transmission technology. gies to ensure members can respond with innovative strategies by
AGMA defined an education opportunity whereby we produce embracing the opportunities.
new classes that support our
design engineers, as well as our
line operators. AGMA recently
received IACET accreditation
ensuring that our programming
is now more valuable and can be
leveraged by employees to secure
continuing education credit.
In the past year, we have
grown our trade show and will
partner with organizations for
continued growth while incor-
porating the customer’s view-
point on technology.
In the past year, we have pro-
duced emerging technology pan-
els, information sheets, and links
Bevel Gears India listens to a presentation at the 2017 Annual Meeting.
via agma.org that keep members (Courtesy: AGMA)
informed in new and different ways.
JANUARY  2018 15

Dean Burrows and Jim Bregi at the 2017 Annual Meeting. (Courtesy: AGMA)
• We are collaborating in new ways with other groups to ensure
AGMA events are the platform for engineers to find com-
mercial innovation.
• We are producing new education programming, so our members’
employees have the tools they need to innovate the products they
design.
You wonder how this will benefit your business?
Give it a try. Join a committee and start figuring out why
hundreds of AGMA members are participating in one. We have
the Emerging Technology Committee, Tradeshow Committee,
Annual Meeting, and SRN Committees that many are already
involved in. Find out why they are volunteering on the Education
Committee, Industry Voice Committee, and Membership
Committee, too. And let’s not forget the 23 different Technical
Committees we oversee and manage on behalf of our industry.
There is something for everyone.
AGMA is driving toward a return on investment for your
participation.
We’re helping you sell more.
We’re helping you learn more.
We’re helping you go global.
We’re helping you connect to new ideas and people driving those
ideas.
We’re helping you go technical.
All for one thing: innovation.
With an innovation-oriented mindset, you can do anything. It’s
the lifeblood of our industry, and it’s what will ensure AGMA,
and its members, will be around 100 years from now.
Get involved: Innovators wanted!
American
Gear Manufacturers
16
Association
gearsolutions.com
IT’S ANNUAL
MEETING TIME!
The 2018 AGMA/ABMA Annual Meeting
registration is now open.
The 2018 Annual Meeting combines the expert knowledge of the
gear and bearing industries with the latest emerging technologies that
influence manufacturers and suppliers. More than 300 executives will
gather in Naples, Florida, in April to experience the information-
packed week full of top-tier speakers. Members will be connected
to innovation and opportunities in the industry with potential to
strengthen business connections and relationships. Join AGMA
and ABMA for an event that is tailored directly for our members to
address trends, successes, and future possibilities. 
Be a sponsor
Are you going to attend the Annual Meeting? Wouldn’t you like your
logo to be visible for all to see? Sponsor one of the many parts to the
Annual Meeting and get your company name out there.
All sponsors will receive:
• Company logo on the annual meeting web page with links to
your company’s website from the time of securing the sponsorship
through the post-meeting press activities.
• Your company’s logo will be printed in all materials for the meet-
ing and in the onsite program. The earlier you sponsor, the more
times your logo will be seen.
• Printed signs and video screen recognition during the event
• Specific recognition for the item/event.
Visit www.agma.org/events/agma-abma-annual-meeting/ to see the
spaces available and fill out the sponsorship form to get started.
Please contact Madelaine Morgan for any sponsorship inquiries at
morgan@agma.org.
AGMA provides students
with new online learning
management system
Distance Education does not seem so distant with the new education
portal for online courses.
AGMA has implemented Elevate, a new online Learning Management
System (LMS) through CommPartners. The system enhances course
offerings by providing an online platform that allows interaction beyond
the scheduled class dates. The new platform was chosen by AGMA to
provide a cleaner and more user-friendly experience for the global com-
munity. The goal was for students attending an AGMA online course
to receive the same experience as they would in a face-to-face course.
Don’t forget to Dean Burrows presents
nominate your Joel Neidig with the Next
Generation Award in 2016
outstanding at the Annual Meeting.

employee for (Courtesy: AGMA)

the AGMA Next

Generation Award
Deadline: January 31
Take the time to recognize your employee
who goes above and beyond in our industry.
Each year, AGMA recognizes an individ-
ual responsible for one or more significant
achievements and, through his or her efforts
and work, has enhanced or strengthened the
gear industry and/or AGMA. We are asking
our member companies to make us aware of
your stars by submitting a nomination for the
AGMA Next Generation Award. Information
is available on our website.  The deadline is
January 31. For more information contact
Jill.johnson@agma.org.

AGMA to host first international course in Mumbai, India

February 22-23
AGMA has partnered with Ovako, Virgo Communications, and the
IPTEX/GRINDEX Show in Mumbai, India, to host its first interna-
tional course: Steels for Gear Applications. The one-day class will be
during the tradeshow at the Bombay Exhibition Centre, and attendees
will have the option of attending on February 22 or 23. AGMA will
offer this course as the first of many outside the United States as part
of its global initiative in the AGMA strategic plan. Make sure if you
attend to look out for the AGMA booth.
Register at: https://www.agma.org/education/advanced-courses/
steels-for-gear-applications/

Follow AGMA on LinkedIn, Facebook, and Twitter

We have enjoyed connecting to many of you on social media and
love seeing the pictures and stories our members share about their
businesses and employees. We want to continue to grow our follow-
ing and see all that is going on out there in the gear industry. Follow
“American Gear Manufacturers Association” on LinkedIn, @agma
on Twitter and @AGMAGear on Facebook. See all the opportuni-
ties AGMA has to offer with education, conferences, foundation
items, and emerging technology. Stay connected to AGMA so we
can be there for you.

Thank you to our guest bloggers; please send more

Thank you to those who have sent in ideas and articles for the
blog. We have had a great response to Gears Matter and we want
to keep the information flowing for our readers. We are looking for
300-400 words on any topic that might relate to the gear industry,
and what better way than to have our members share their own
thoughts or ideas? We have entries on foundations, communications,
standards, and emerging technologies, to give you some ideas. If you
are interested in becoming a guest blogger, please contact Rebecca
Brinkley at brinkley@agma.org.

There are some great events planned for 2018, go to www.agma.org for the full schedule and details.

AGMA has over 1,000 Twitter followers! Join the conversation @agma

1001 N. Fairfax Street | Suite 500 | Alexandria, VA 22314 | (703) 684-0211 | www.agma.org
JANUARY  2018 17
 CALENDAR OF EVENTS
Whether you’re 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 an email to events@agma.org.
Events are open to AGMA members only. Not a member? Send an email to membership@agma.org.

January 16 — Nomenclature Committee Meeting — WebEx

January 16 — Spline Committee Meeting — WebEx
January 17 — Bevel Gearing Committee Meeting — WebEx
January 18 — Gear Accuracy Committee Meeting — WebEx
JANUARY

January 19 — Powder Metallurgy Committee — WebEx

January 23-25 — Gearbox System Design — Las Vegas, Nevada
January 23-24 — Working Group 13 Meeting — Alexandria, Virginia
January 25 — Lubrication Committee Meeting — WebEx
January 29-30 — BMEC Meeting — Orlando, Florida
January 31 — Helical Gear Rating Committee Meeting — WebEx

February 1 — Helical Gear Rating Committee — subcommittee 925 Meeting — WebEx

February 5-7 — Gear Materials — Clearwater Beach, Florida
February 6-9 — Working Group Meetings — Milan, Italy
FEBRUARY

February 7-8 — Plastics Committee Meeting — Orlando, Florida

February 12-13 — Aerospace Gearing Committee — Orlando, Florida
February 15 — Metallurgy and Materials Committee Meeting — WebEx
February 16 — Nomenclature Committee Meeting
February 19-20 — Spline Committee Meeting — Chicago, Illinois

AGMA LEADERSHIP

Jim Bregi: Chairman Nitin Chaphalkar: DMG Mori USA

EXECUTIVE COMMITTEE

Doppler Gear Company

Michael Engesser: Reishauer Corporation
John Cross: Treasurer
ASI Technologies Inc. David Long: Chalmers & Kubeck Inc.
BOARD OF DIRECTORS

John E. Grazia: Chairman, BMEC Michael McKernin: Circle Gear and Machine Company
GearTec Inc.
Todd Praneis: Chairman, TDEC Cory Ooyen: Global Gear & Machining, LLC
Cotta Transmission Company, LLC Carl D. Rapp: The Timken Company
Dean Burrows: Chairman Emeritus
Gear Motions Inc. Tania Sabados: Rapid Gear
Andrea Scanavini: Somaschini North America
Matt Croson: President
Greg Schulte: Bonfiglioli USA
Amir Aboutaleb: Vice President, Technical Division
STAFF

Jenny Blackford: Vice President, Marketing Brian Schultz: Great Lakes Industry, Inc.
Jill Johnson: Director, Member Services George Thomas: Bison Gear & Engineering Corp.
Casandra D. Blassingame: Director, Education Hastings Wyman: Klingelnberg America, Inc.
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

18 gearsolutions.com
We’ll Keep You

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Forest City Gear’s exceptional reliability means you’ll sleep
better at night. Safeguard your next gear production project.

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Excellence Without Exception

 MATERIALS MIKE BURNETT
MATTER
TECHNOLOGIST
TIMKENSTEEL CORPORATION
MACHINABILITY AND THE COST OF MANUFACTURING GEARS
Taking material modifications into consideration can play an important role
in reducing overall machining costs. Here are some helpful tips.
WHEN IT COMES TO MATERIAL-ASSOCIATED GEAR MANUFAC-
turing costs, machining and gear-tooth cutting costs stand out as
primary contributors. The gear blank and tooth machining costs are
further dependent upon the machine tool/machining methods used
and the associated cutting insert/tool. The interaction between the
tools and the base material determines the life or number of parts
cut on each tool. For many machining operations, the advances in
machine tool and insert/coating technology have greatly reduced
the overall per-part machining costs regardless of the base material
properties. However, there remain a few operations where the per-part
cost can be quite high.
Historically, each alloy grade had associated with it an appropriate
thermal treatment that would be applied to optimize the machining
characteristics, as follows:
• Low carbon/alloy: Reduced cooling from hot working, normalize,
and/or temper.
• Medium carbon/low alloy: Normalize and temper or fine pearlitic,
lamellar anneal.
• Medium/high carbon/alloy: Coarse lamellar pearlitic or partial
spheroidize anneal.
• High carbon: Fully spheroidize anneal.
A) B)
D) E)
Figure 1: Representative photomicrographs of ferrite/pearlite A) low carbon, B) medium carbon and C) high carbon steels, and ferrite/bainite D) low carbon, E) medium carbon
and F) high carbon steels.
20 gearsolutions.com
However, the more robust machining operations have made these
annealing cycles optional for many applications, and instead, the
annealing costs might be weighed against the increased machining
costs or subsequent heat treatments required to regain properties.
As such, many applications are now machined in a semi-hard state,
reducing the thermal treatment costs while maintaining the core or
base properties required for the application.
The typical method to approach improving machinability of steel parts
such as gears involves improvements in the machine tool arena of the
operations including the machine tool itself, the cutting tools used for the
operation, and perhaps the coolant type and flow. However, there are also
opportunities to improve the machinability of gears through optimiza-
tion of the metallurgical properties of the gear materials going into the
machining operations. Historically, improvements in steel machinability
had been accomplished by adding inclusions to aid in chip formation and
improved tool wear; however, these additives are deleterious to the gear
properties, and the improved property requirements for premium gears
have reduced the acceptability of this approach. Alternatively, machining
improvements can be accomplished through an alloy design or selection
approach, a thermal treatment applied prior to the machining operations,
or some combination of these.
C)
F)
Figure 2: Comparison of the effect of carbon level (a) and hardness (b) on the number potential gears that can be broached between tool regrinds for both structure types
One such operation that lends itself well to material optimiza-
tion to reducing machining costs is broaching of gear teeth, and
in particular internal helical ring gears. Broaching is a machining
technique commonly used to cut gear teeth where the tooth profiles
can be formed in a single machining operation with minimal overall
time, making it ideal for cost-sensitive applications [1]. However,
in order to accomplish the broaching operation in a single station
and operation, the broach machine must perform the entire rough-
ing, shaping, and finishing of the desired part profile in one step
using a long, multi-piece, high-speed steel broach tool. The precise
broaching and tooling cost per manufactured part is highly depen-
dent upon the number of parts that can be manufactured between
broach tool redressings. With tooling and redressing costs over the
life of a helical broach bar on the order of $70,000 to $100,000,
and total parts manufactured on a single broach bar currently in
the range of 10,000 to 80,000 parts, the cost to broach a part is
typically in the range of 60 cents to $5 or more. Hence, the broach
tooling cost represents around 15 percent to 50 percent of the total
manufacturing cost for a finished part.
Reduction of broaching costs is normally accomplished through
developments of tooling materials, coatings, lubricants, and process-
ing parameters without as much attention given to the influence of
the material condition of the part being broached [2]. In order to
study the influence of steel material condition on broach tooling life,
a laboratory broach test machine was conceived, developed, built, and
used to perform numerous studies on the broaching characteristics of
various steel grades. This test method and results are described fully
in References 3 and 4 and will be summarized here to illustrate the
material impacts on machining costs.
A series of steels typical of both carburizing and induction harden-
ing gear applications were selected for testing. The steels were tested
in both the typical baseline, ferrite/pearlite, and modified conditions
(ferrite/non-pearlite or bainitic), with the intent to improve upon
the baseline broach life results. These steels and the heat chemistries
include low- to medium-carbon grades (0.20 to 0.60 wt. percent C),
with varying alloying combinations (Mo, Cr, Cr-Mo, Cr-Ni-Mo,
Mn, Mn-V) and hardness levels. The broach life results are shown
in the attached plots for varying carbon and hardness levels and the
two variant starting structures (ferrite/pearlite vs ferrite/non-pearlite).
See Figure 1.
The non-pearlitic structure has been shown to achieve greatly
increased broach life conditions over a similar range in carbon
ABOUT THE AUTHOR: Mike Burnett is a technologist at TimkenSteel. Learn more at www.timkensteel.com.
and hardness levels, as compared to the pearlitic conditions.
These results allow for significant flexibility in steel selection and
core hardness levels, while maintaining reasonable broach costs
throughout. The non-pearlitic conditions develop an entirely
different carbide structure as compared to the pearlitic carbides.
The fine, spheroidal type carbides present in these tempered and
non-tempered steels are much less abrasive to the broach tool,
allowing for greatly enhanced tool life results. As such, using this
technology would allow for achieving the low cost structure of
the low carbon carburizing grades with the core properties and
hardening characteristics required for higher carbon induction
hardened gears. See Figure 2.
SUMMARY
The costs associated with gear machining can be quite high, and
where improvements with tooling advances alone are insufficient,
material modifications may be useful to further reduce the overall
machining costs. Whereas historically the raw material going into
gear machining operations were annealed in a grade specific fashion,
that is now sometimes being modified to result in the lowest overall
cost to manufacture the gear application. These modified process
routes are typically driven by improvements in machine tool and
tooling advances, but additionally optimization of the gear blank
material can result in large improvements in machining costs or
increased options for manufacturing options and routes. The example
of what has been accomplished for helically broached gears is sum-
marized here, which can be used to improve broach tool life for a
given application or used to determine cost optimized materials and
process routes for new gears. 
REFERENCES:
1. C.V. De Motter, “The Art and Science of Broaching,” Gear
Solutions, March 2007, pp. 30-35, 50.
2. V. Schulze, H. Meier, T. Strauss and J. Gibmeier, “High Speed
Broaching of Case Hardening Steel SAE 5120,” SciVerse Science
Direct, 5th CIRP Conference on High Performance Cutting
2012, pp. 431-436.
3. M. E. Burnett, “Enhanced Broaching Steel Technology,” SCT
2014, 4th Intl Conference on Steels on Cars and Trucks, June
15-19, 2014, Braunschweig, Germany, pp. 141-148.
4. M. E. Burnett, “Improved Broaching Steel Technology,” Gear
Technology, July 2016, pp. 44-49
JANUARY  2018 21
 TOOTH BRIAN DENGEL
TIPS
GENERAL MANAGER
KHK-USA
MAKING THE BEST SELECTION
There are different types of gears to choose from depending
on the orientation of the application.
IN TODAY’S ONLINE DATING WORLD, YOU ARE ASKED SEVERAL
pointed questions in order to determine your perfect match. Just like
human relationships, gears work best when they are properly matched.
In order to find the proper style of gear for an application, the
first consideration needs to be what gear type will fit with the shaft
orientation of the system. The possibilities are:
• Parallel axes.
• Intersecting axes.
• Nonparallel and nonintersecting axes.
Once the determination of shaft orientation is made, the second
decision involves the speed ratio requirements. Certain styles of
gearing can provide high speed ratios, whereas others are limited to
small ratios.
For parallel axes applications, the most common style of gear is
the spur gear. This style of gear is cylindrical in design and has the
teeth cut parallel to the axis of the bore. This is the most common
style of gear and is quite versatile, as it can be mated with either
another spur gear or with a gear rack. A great advantage of spur gears
is that you can combine two gears of the same pitch and pressure
angle regardless of the number of teeth on each gear. This allows for
an infinite variety of fractional speed ratios. The limitation is that
it becomes impractical to produce speed ratios greater than 10:1, as
the pitch diameter of the larger gear typically becomes too large for
the design envelope.
The gear rack is another parallel axis style of gear. The design of a
gear rack is technically that of a spur gear that has an infinite pitch
radius. A gear rack can mate with any spur gear that has the same
pitch and pressure angle. They have the advantage of being able to
be produced with finished ends, which permit racks to be butted end
to end in order to form an infinite length of rack.
A third style of parallel axes gearing is the helical gear. This is also a
cylindrical gear, but its teeth are produced in a helicoidal form. These
gears function identically to spur gears with regard to having an infi-
nite number of fractional speed ratios available. However, due to the
helicoid, they do have two other requirements. The first requirement
is that they mate only as opposite hands. A right-hand helical pinion
can only mate with a left-hand helical gear, provided they both are
the same pitch, have the same pressure angle, and have the same helix
angle. The same applies to a helical rack. A left-hand helical rack can
only mate with a right-hand helical pinion, provided they both have
the same pitch, pressure angle, and helix angle. The second require-
ment is that helical gears require thrust bearings to be used in order to
absorb the thrust loads produced by the helicoid mesh. The last style
of parallel axes gearing is the herringbone gear. This unique gear is a
combination of two adjacent helical gears of the same pitch, pressure
angle, and helix angle, but opposite hands. The configuration allows
for the full use of all of the benefits of helical gearing (additional load
capacity, quieter operation) without the thrust loads.
22 gearsolutions.com
For intersecting axes, the most common style of gear is the bevel
gear. The term bevel gear is used to describe both a specific type of
gear and any of a variety of derivatives of this style. When bevel gears
are mated with a speed ratio of one-to-one, they are called miter gears.
For any other ratio they are called bevel gears.
Although bevel gear sets can be produced with fractional speed
ratios greater than one-to-one, the pinion and gear are produced such
that they will only mate with one another at a certain intersecting
angle. Most bevel gears are produced for intersecting shafts set at 90
degrees, but there are bevel gears produced with shaft angles as small
as 45 degrees and as large as 135 degrees. The most common style of
bevel gear is the straight tooth bevel gear. This gear has teeth that
are a tapered conical form and lay in the same direction as the pitch
cone base line. The standard bevel gear tooth form is identical for
both the bevel pinion and the bevel gear. This becomes a limiting
factor for large speed ratios as the pinion is inherently weaker than
the gear. The Gleason bevel gear tooth form considers the speed ratio
of the bevel gear set to determine the tooth shape of both the pinion
gear and the bevel gear and enlarges the pinion tooth in higher ratio
sets. Even with this additional compensation for tooth loading, bevel
gear sets are typically limited to speed ratios of six to one.
The second most common bevel gear style is the spiral bevel gear.
The tooth of the spiral bevel gear is similar to that of a helical gear
in that the tooth is produced at an angle to the bore axis. Spiral bevel
gears are also produced such that if the pinion has a left-hand spiral,
the mating bevel gear must have a right-hand spiral of equal angle.
The most common spiral angle for bevel gears is 35 degrees. Similar
to the thrust loads produced by the helix angle, there are thrust loads
in spiral bevel gears that result from the spiral angle.
A third tooth style for bevel gear sets is the Zerol bevel gear. This
style of bevel gear is a hybrid that lies between the straight tooth
form and the spiral tooth form. Unlike the spiral bevel gear in which
the tooth is generated at an angle to the axis, the Zerol gear tooth
is generated at an angle of zero degrees but unlike the straight tooth
bevel gear where the tooth is a taper conical form, the Zerol gear
tooth is curved. This results in a spiral bevel style gear that mimics
the loading pattern of a straight tooth bevel gear. A specialty case of
intersecting axes gearing is the face gear. This is a gear set in which
a spur gear is used as the pinion and a disc with tapered teeth is
used as bevel gear. This style offers no operational advantages over
a standard bevel gear set.
For nonparallel and nonintersecting axes applications, the most
common style of gear is the worm gear pair. This pair of gears includes
the worm wheel, which is basically a helical gear, and a worm, which
is screw thread that matches the pitch, pressure angle, and helix angle
of the worm wheel. The speed ratio of a worm gear pair is determined
by the number of teeth on the worm wheel and the number of thread
starts on the worm. For worms with a single thread, very high speed
ratios can be developed. When adding additional thread starts, the
Spur gears are cylindrical in design and have the teeth cut parallel A Zerol bevel gear is a hybrid that lies between the straight tooth form
to the axis of the bore. and the spiral tooth form.

helix angle needs to increase if the center distance is to remain the
same. Another type of nonparallel-nonintersecting gear is the screw
gear (also known as a crossed helical gear). This is a helical gear set
in which the gears operate any angle greater than zero degrees. The
most common angle is 45 degrees. As with helical gears, an infinite
variety of fractional speed ratios are possible, but due to the mesh
being point contact, these gears have a limited load capacity.
A specialty case of nonparallel-nonintersecting axes gearing is the
hypoid bevel pair. In this set, the larger gear looks similar to a spiral
bevel gear; however, the pinion sits offset to the intersecting axis,
and its tooth form resembles a tapered thread. Similar to worm gear
pairs, the speed ratio of a hypoid set is determined by the number
of thread starts on the pinion relative to the number of teeth on the
mating gear. As such, a hypoid configuration can result in very high
speed ratios in a very compact space.
As detailed in these examples, there are many distinct styles of
gearing. Each has a purpose, and each application will dictate what
style should be selected. 

ABOUT THE AUTHOR: Brian Dengel is general manager of KHK-USA, which is based in Mineola, New York. Go online to www.khkgears.us.

RUSSELL, Precision Gear Products

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 HOT D. SCOTT MACKENZIE, PH.D., FASM
SEAT
SENIOR RESEARCH SCIENTIST-METALLURGY
HOUGHTON INTERNATIONAL INC.
OIL QUENCHANTS UNDERSTANDING THE CHEMISTRY (PART I)
This installment explores the chemistry of oil quenchants and the effects of additive
packages on quenching performance, to be followed in February by a discussion of base oils.
OIL QUENCHANTS HAVE BEEN USED EXTENSIVELY TO HARDEN
steel in excess of 100 years. There are a wide variety of commercially
available quenchants on the market, from nearly as many different
producers. This column explores how the chemistry of the base oil
and additive package affects quenching performance. A discussion
of the mechanism of oil degradation also will be provided. This will
be broken into two sections: first a description of quench oils, and
the second part will be a description of the oxidation of quench oil
and ramifications for the heat treater.
Many types of oils have been used for quenching, including veg-
etable, fish and animal oils, and particularly sperm whale oil have
been used for quenching operations. The first petroleum-based
quenching oils were developed about in 1880 by E.F. Houghton in
Philadelphia. Since that time, many advancements have been made
in the development of quenching oils to provide highly specialized
products for specific applications.
A wide range of quenching characteristics can be obtained through
careful formulation and manufacturing. High quality quenching oils
are formulated from refined base stocks of high thermal stability.
Selected wetting agents, antioxidants, and accelerators are added to
achieve specific quenching characteristics. The additions of these
complex anti-oxidant packages are included to maintain perfor-
mance for long periods of continued use, particularly at elevated
temperatures. Emulsifiers may be added to enable easy cleaning
after quenching.
Petroleum-based quench oils can be divided into several catego-
ries, such as quenching speed, operating temperatures, and ease of
removal. The simplest category is operational temperature: Cold
oils for operation below 90° C and mar-tempering oils used for
temperatures above 90° C.
Cold oils are the most widely used oils for heat-treating applica-
tions. These oils are further broken down into rankings according
to speed or heat extraction. These are usually called slow-, medium-,
and high-speed oils.
Normal-speed quench oils have relatively low rates of heat extrac-
tion and are used in applications where the material being quenched
has a high hardenability. Highly alloyed steels such as AISI 4340 or
tool steels are typical examples of steels quenched in normal speed
oils. These oils usually have a maximum quench rate below approxi-
mately 60° C/s (108° F/s).
Medium-speed quench oils provide intermediate quenching char-
acteristics and are widely used for medium to high hardenability
applications where dependable, consistent metallurgical properties are
required. These oils have a maximum cooling rate between 60° C/s
to 90° C/s (108° F/s to 162° F/s). This is the most widely used group
of cold oils, primarily because of the wide applicability.
High-speed quench oils are used for applications such as low
hardenability alloys, carburized, and carbo-nitrided components, or
large cross-sections of medium hardenability steels where high rates
24 gearsolutions.com
of cooling are required to ensure maximum mechanical properties.
High-speed quench oils usually have a maximum cooling rate greater
than 90° C/s (162° F/s). A comparison of the quenching speeds of the
different types of quench oil is shown in Figure 1.
Mar-quenching oils are a special case where the part is quenched
into a quenchant at elevated temperature, typically 100° to 200° C.
The work piece is held in the quenchant until temperature equi-
librium is established throughout the section and then air-cooled
to ambient temperature. During mar-quenching, components are
quenched to an intermediate temperature close to the Martensite start
(Ms) temperature and held at this temperature. This eliminates the
temperature gradients across the surface, and consequently, during
subsequent slow cooling after removal from the hot oil, transforma-
tion to Martensite occurs uniformly throughout the section. This
minimizes the generation of internal stresses and reduces distortion.
Since mar-quenching oils are used at relatively high temperatures,
their formulation and physical properties are different from cold
quenching oils. They are formulated from carefully selected base
stocks with high oxidation resistance and thermal stability. They have
high flash points and viscosities and contain complex anti-oxidant
packages to provide long life. Selection of the mar-quenching oil is
based on the operating temperature and quenching characteristics.
A minimum of 50º C should be maintained between the operating
temperature of the oil and its flash point.
ADDITIVE PACKAGES
Additive packages have two functions: first to act as a speed improv-
er, and second to increase thermal and oxidative stability. These
additives can have a dramatic effect on the quenching properties.
The magnitude of the effect is dependent on the additive package.
These additive packages are usually proprietary. Depending on
the robustness of the additive package, they may tend to deplete
during use. Some additive packages are prone to selective drag-out
over time. It’s generally not appropriate to mix additive packages
from different quenchant suppliers because of the unintended
consequences of precipitation, increased staining, and generally
unpredictable response.
Speed improvers increase the quenching rates by increasing the
wettability of the oil. There are different types of additives. The
most common is the sulfonate-type. Barium sulfonate used to be
the most common, but it is no longer used by most quenchant
suppliers. The presence of barium can cause an issue with disposal
and special precautions during disposal. Potassium and sodium
sulfonates are commonly used. These sulfonates provide excellent
speed improvement and can double as thermal oxidation stabiliz-
ers. However, if oil is recovered from washers and reused (after
eliminating water), the soluble sodium sulfonates can be depleted
from the quench oil. This can lead to a greater emulsified layer of
oil in the washer, contributing to poor recovery yield. It can also
 contribute to poorly washed
parts. Hydrocarbon based addi- Cooling Rate, °C/sec
tive packages are used in high- 0 20 40 60 80 100 120
900
end quenchants. They are robust
and have a long life and are not 800
prone to replenishment. The pri-
mary disadvantage is cost. 700
The other purpose of an addi-
tive package is to improve the 600

Temperature, °C
thermal and oxidative stability
500
of the base oil. These packages
reduce the formation of sludge 400
and minimize the formation of
organic acids upon thermal aging 300
of the oil.
200
CONCLUSIONS
100
In this column the different types
of quench oil were described, and 0
the constituents in commercially 0 10 20 30 40 50 60
available quench oil examined. Time, sec
Part 2 will address base oils,
Slow Speed Oil Medium Speed Oil Fast Speed Oil
while the oxidation of oils and
the interaction of anti-oxidants
will be discussed in upcoming Figure 1: Comparison of cooling curves of slow-, medium-, and fast-quench oils. Oils were tested at 60° C per ASTM D6200.
installments. 

ABOUT THE AUTHOR: D. Scott MacKenzie, Ph.D., FAS, is senior research scientist-metallurgy at Houghton International Inc.
Go online to www.houghtonintl.com.

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 COMPANY
PROFILE

Bevel Gears (India) Pvt. Ltd.

Bevel Gears (India) make bevel gears

from about a quarter of an inch up to 80
inches. (Courtesy: Bevel Gears (India))

26 gearsolutions.com
Bevel Gears (India) Pvt. Ltd. has designed and manufactured bevel
gears and bevel gearboxes for more than 40 years. 

By Kenneth Carter
Editor | Gear Solutions
BEVEL GEARS (INDIA) PVT. LTD. CONSIDERS ITSELF
a “niche within a niche” when it comes to making and
supplying bevel gears.
“Our niche is bevel gears,” said Mushtaq Jamal, vice
president of engineering and business development with
Bevel Gears (India). “We manufacture straight, spiral,
hypoids, and high ratio hypoids.”
That niche within a niche comes from being able to
offer a wide variety of bevel gears, according to Jamal.
“If a company does straight bevel gears, it doesn’t
mean that they can do spirals,” he said. “And if they
do spirals, it doesn’t mean they can do hypoids. And if
they can do hypoids and spirals, it doesn’t mean they
can do spiral grinding or angular bevels. We also offer
straight bevel grinding that is a capability that normally
has customers asking us to repeat what we said because
so few companies offer the service. We manufacture
4-tooth hypoid pinions and recently developed high
ratio hypoids for a 1:60 set with a single-tooth pinion.
It’s all a niche within a niche. When you factor into
that the different sizes, then what really sets us apart is
the fact that we do all these types of bevel gears and all
these different aspects and sizes of them. Add the bevel
gearbox line and it is an additional dimension for our Bevel Gears (India) can specifically produce a single gear set for a
customers to leverage.” customer if needed. (Courtesy: Bevel Gears (India))

VARIETY OF SIZES SPECIALIZED SERVICES

Not only does Bevel Gears (India) make an assortment
of bevel gears, but it can produce them in a variety of
sizes. It is also one of the few companies that offers both
Gleason and Klingelnberg bevel gear systems.
“We make bevel gears from about a quarter of an inch
up to 80 inches,” Jamal said. “And for bevel gears, that’s
a very broad range by global standards.”
Bevel Gears (India) does a lot of specialized work and
has diversified and serves several markets, including min-
ing, defense, robotics, medical, and the steel and crushing
industries, according to Jamal.
While some companies focus on automotive work,
Bevel Gears (India) has taken its bevel gear expertise in
a different direction. The approach is for a higher mix
with lower volumes, which customers appreciate.
“On our brochure, we basically say that we’re a one-
stop shop — as cliché as that may sound,” he said. “It’s
really a very broad spectrum of what we offer. Many
people are surprised to hear that several of our custom-
ers are other gear manufacturers. We export about 40
to 50 percent of our business around the world with
customers ranging from service repair shops to inter-
national OEMs.”
He added that presently a large portion of BGI’s global
exports are for the North American and European markets.
Bevel Gears (India) also can reverse engineer or redesign
specific gears, and the company is capable of producing
smaller gears for a customer in the thousands. When those
bevel gear orders require larger sets of 40 inches or larger,
Bevel Gears (India) can specifically produce a single gear
set for a customer if needed.
“It’s been a very interesting journey, because it intro-
duces you to so many different industries,” he said.
“When I joined the company I never thought these would
go into so many different places — literally. We have
manufactured bevel sets for truck prototypes to washing
machines, master ground spiral sets to robotics to ratio
changes for ATV’s and rally cars, to reverse engineering
legacy jet engines. In several instances, we have custom-
ers who know their respective market-specific products
and know their parts, but they don’t really know the
gearing aspect of it. When this situation arises, we try
to assist with improvements or design tips, and it is well
received. As a policy, we believe in relationship building,
which then becomes the foundation of forging business
relationships.”
When a customer is looking at robots on a manufac-
turing line, that customer is more concerned with where
those robots are going and what tolerances have to be
met and maintained. For another business, a customer
JANUARY  2018 27
A 4-tooth hypoid gear. (Courtesy: Bevel Gears (India))

might need gears for an industrial gearbox for a 50-year-old design prior to when India was considered a global gearing provider. In 2012,
with only a rough sketch to work with. we hosted and coordinated an AGMA delegation to India,” Jamal
said. “About 22 AGMA members came across. We coordinated visits
“It may be the same product, but what they want out of it is entirely
to several different companies around the country, and it allowed
different — strength or part fit and function or vibration sensitivity
the participants to see and assess firsthand the gearing capabilities.
at high rpm’s,” Jamal said. “The job specific aspects can vary, but the
quality is a constant that has to be maintained, and we continually Sulaiman Jamal, the company founder and managing director, was
strive to improve this area.” invited to join the AGMA board of directors in 2011, which I believe
is the first time someone from the Indian subcontinent has been asked
MADE TO PRINT to do so. That was a very proud moment for all of us.”
About 90 to 95 percent of the gears Bevel Gears (India) produces are Sulaiman Jamal’s endeavor has definitely come a long way since
made to print, according to Jamal. he began the company in 1976 in a 200-square-foot office, and the
“So the customers already have what they want, and they come to company’s recognition has increased exponentially within the gear
us for the execution,” he said. industry, according to Jamal.
The remaining percentage of the company’s gear work involves “Originally, he used to work for another gear manufacturer,” he
reverse engineering, design, and standard bevel gearboxes. said. “And that company was higher-production-quantity focused.”
“This is something that not every bevel gear shop has,” Jamal
said. “In certain instances, if customers want improved strengths, A NEW FUTURE
ratio changes, stronger materials, or design analysis to be done, But Sulaiman Jamal had a vision to branch out and get into produc-
then we provide that value as well. It’s not just, ‘give us your ing smaller bevel gears, and when the company he worked for wasn’t
print, we’ll make you a part.’ If they want a deeper dive, then we interested in going down that path, he left and pursued that dream
can do that.” on his own.
“Sulaiman started out with a single 2-tool straight bevel generator
AGMA ACTIVE he bought at an auction,” Jamal said. “His first customer was actually
Bevel Gears (India) is also active with the American Gear IBM in the ’70s, who required gears for the punch card machines.
Manufacturers Association (AGMA). This was at a time when the domestic market was in its infancy.
“AGMA has been an invaluable association for us. From the net- Today we have over 75 bevel and bevel-related machines and have
working to the Gear Expos to the standards and committees, the team a team of nearly 100 people. He still maintains that you have to be
has been welcoming and the Association as a whole has been very very passionate about this business to persevere and succeed, and it
rewarding. We have been participating at Gear Expo since the 1980s is sound advice.”
28 gearsolutions.com
“We have manufactured bevel sets for truck prototypes to washing machines, master ground spiral sets to robotics
to ratio changes for ATV’s and rally cars, to reverse engineering legacy jet engines,” said Mushtaq Jamal, vice
president of engineering and business development. (Courtesy: Bevel Gears (India))

As Bevel Gears (India) continues to “It’s a very interesting time to be involved

grow, Jamal said he expects the company to
continue with further specialization with
bevel gears while expanding select interna-
tional territories and applications. In the
near future, the company plans to have a
dedicated facility for aerospace with 5-axis
machining centers and CNC gear inspec-
tion. The aim is to be a model gear shop
that would do India proud both in capability
and technology.
in the gear industry and to see what’s pos-
sible with the new CNC capabilities of next
generation machinery,” he said. “When you’re
driven by need and desire, it’s very interesting
to see what you can achieve.”
But in the here and now, Jamal said Bevel
Gears (India) will continue to make some of
the smallest and largest bevel gears, compet-
ing on a global stage with some of the biggest
names in the industry. 

FOR MORE INFORMATION: www.bevelgearsindia.com

JANUARY  2018 29
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. (AGMA) This paper was presented October 2017 at the AGMA Fall Technical Meeting in Columbus, Ohio. 17FTM15

30 gearsolutions.com
Fatigue Performance and
Cleanliness of Carburizing
Steels for Gears
This investigation shows that steels with a higher cleanliness level reach
a higher performance level as well, both in terms of increased loads
and longer service life.
By Joakim Fagerlund, MSc, and Lily Kamjou, MSc
The cleanliness of steels used for gears is of great impor-
tance when looking to improve their life or increase
loads. In this paper, carburizing steels with the same
basic chemical composition, but with a varying cleanli-
ness level, are compared in regards to cleanliness and
performance. Steel cleanliness can be described as size
and frequency of non-metallic inclusions in steel, such as
Al2O3-MgO particles. Rotating bending fatigue has been
used to evaluate the fatigue performance of carburized
samples. For this purpose, samples are taken transverse to
the rolling direction of the bar, whereas normally, samples
Figure 1: Empirical relationship between inclusion size, stress, and the
are taken in the longitudinal direction. The aim has been
number of cycles to failure in rotating bending fatigue testing.
to test the method in itself, as well as the most critical
loading direction, since this determines the worst-case
scenario of the inclusion orientation when forging a gear
out of a steel blank.
To determine material cleanliness, a standard micro-
inclusion rating method such as ASTM E45 has been
used in combination with automated inclusion assessment
by scanning electron microscope (SEM) and 10MHz
immersed ultrasonic evaluation. The investigations show
a good qualitative correlation between fatigue perfor-
mance and inclusion assessment made by ultrasonic
evaluation and SEM. The results also show that tradi-
tional micro-inclusion rating methods are not sensitive
enough (i.e., the evaluated areas are too small) to give a
good indication of material performance. Fatigue testing
in the transverse direction of the bar proves to be a good Figure 2: Fracture surface of sample exposed to cyclic bending (cause
technique that can more relevantly determine fatigue of fracture spherical inclusion with surrounding void).
performance of steels for gears without involving costly
and somewhat complicated gear manufacturing.

INTRODUCTION
As inclusions act as nucleation sites for crack growth
under cyclic loading, steel cleanliness is an increasingly
important factor for gears as well. This effect can be
observed in both torsion/bending/axial loading and con-
tact loading (e.g., gears and bearings). Steel cleanliness
can be described as the size and frequency of non-metallic
inclusions such as oxides (e.g., Al2O3, MgO, and CaO)
and sulphides (e.g., MnS and CaS). Since the presence
of inclusions correlates strongly to fatigue performance,
it is essential to have a good enough knowledge of the
inclusion population in steel that is used for a critical Figure 3: Section of sample exposed to cyclic contact loading (center
component. of picture inclusion with associated crack).

JANUARY  2018 31
 In Figures 1 to 3, examples are presented
to illustrate the effect of stress and inclusion
size on the number of cycles to failure for
hardened bearing steel (∼62 HRC). As can
be seen, inclusion size has a dramatic effect
on the number of cycles to failure (fatigue
performance).
This way of reasoning can be directly trans-
ferred to carburizing steels, due to their hard-
ened surface and the fact that high-strength
steels are limited by fatigue; i.e., they do not
have infinite life.

BACKGROUND
It is essential to be able to quantify the
presence of critical-sized inclusions in steel,
since inclusions strongly affect fatigue and
therefore the ability to assure product per-
formance. Several methods currently exist
to quantify steel cleanliness. For smaller-
sized inclusions, micro-inclusions, polished
samples are investigated with a light opti-
cal microscope (manually or automatically).
Figure 4: Stringer inclusion (Al2O3-MgO), elongated in the rolling direction (longitudinal direction of the bar).
Examples of such methods are: ASTM E45,
DIN 50602, and ISO 4967. Typically, these
methods involve examination of areas in the
range of 100–1,000 mm 2 (0.155–1.55 in.2).
It is obvious that these areas are too small to
detect infrequently occurring inclusions and
therefore cannot be seen to represent the true
inclusion population. For macro-inclusions,
blue fracture testing, which can still be
called for in many specifications, is an inad-
equate evaluation method for clean steels,
since the method is not sensitive enough
and rarely finds inclusions. In order to over-
come the limitations of such methods, other
rating methods can be used to investigate
larger areas. Automatic scanning by the use
of scanning electron microscope (SEM) is
an alternative that can cover approximately
3,000 mm 2 in a few hours. Another way to
find less frequent inclusions is to investigate
volumes instead of areas, and for that type
of examination, ultrasonic inspection is a
possibility. It is, however, necessary to be
aware that some available standards are not
Figure 5: Manganese sulphide inclusion (MnS), elongated in the rolling direction (longitudinal direction of the bar).
stringent enough to find inclusions in clean
steel and that for this method to be useful,
many steel suppliers use other limits than
specified in current standards.

INVESTIGATION
The objective of the investigation was to
evaluate the cleanliness and how it is related
to the fatigue performance of carburizing
steels with similar basic chemistry but with
a varying degree of cleanliness, seeing as this
type of steel is commonly used for different
types of gear applications. Table 1: Chemical composition and production route of investigated steels.

32 gearsolutions.com
 Figure 7: Orientation and position of the center of the
fatigue sample taken from a steel bar.

Figure 6: Rotating bending machine.
The thesis is that steel cleanliness is con-
sidered the limiting factor and will therefore
have a larger impact on performance than
steel chemistry, as long as they are of similar
type. For this paper, different cleanliness levels
have been tested, and the chemistry has varied
somewhat, although all tested materials have
been of a carburizing type steel.
As some inclusion types are deformed or
crushed and elongated in the rolling direction
(see Figures 4 and 5) during hot working, the
result is lower fatigue performance transverse
to the rolling direction, compared to the lon-
gitudinal direction. This is the main reason
for evaluating the transverse fatigue proper-
ties, because it is the worst case of the inclu-
sion orientation in a forged gear. Cleanliness
evaluation has been performed by using SEM
evaluation and 10 MHz ultrasonic immersion
testing [1], as well as micro-inclusion assess-
ment. Fatigue performance was evaluated by
rotating bending fatigue testing.
an alternating stress with an R value of −1 (R
= smin / smax). The staircase method was used to
evaluate the endurance limit with a maximum
number of cycles of 10 million (runout).
SAMPLE PREPARATION
Testing fatigue performance in the transverse
direction is normally more challenging than
testing the longitudinal direction, due to speci-
men length being 120 mm, and therefore quite
often exceeds the diameter of steel bars to be
tested. In this study, the test specimens were
produced from bars in the range of 60 mm to
90 mm. The fatigue specimens were manufac-
tured as follows: The center part of the fatigue
specimen was cut out from the steel bar (the
material to be tested, Figure 7), and turned into
a cylindrical sample (transverse orientation).
Figure 8: Sample preparation. Red line = friction weld.
Figure 9: Finished fatigue specimen.
A cylindrical bar with the same diameter
was then friction-welded onto both ends of
the center sample and then soft-machined
close to final shape, see Figures 8 and 9. Heat
treatment followed soft-machining, carbu-
rizing for approximately 50 hours, in order
to get a through hardening. The reason for
through hardening is to avoid fatigue failures
unrelated to inclusions, for example failures
from the transition zone.

INVESTIGATED STEEL
For this investigation, steels from an ingot
cast route with higher area reduction as well
as steel from a continuous cast route with a
lower reduction ratio were included, as pre-
sented in Table 1. For all steels, a number of
samples has been investigated, and the figures
in the report are the results of these tests.

FATIGUE PERFORMANCE
Fatigue testing through rotating bending has
been performed (see Figure 6 for setup), in
which hourglass-shaped specimens are exposed
to alternating tension and compression stresses
whilst rotating, thus the specimen is exposed to Figure 10: Hardness profile, Steel 1, pre-turned and heat treated.

JANUARY  2018 33
 An example of the measured hardness pro-
file as seen in Figure 10, and the surface
hardness of the tested samples can be seen
in Figure 11.

RESULTS OF FATIGUE TESTING

This paper is based on three sets of tests
performed. The initial testing [2] was per-
formed to prove the validity of the method,
with friction-welded, through-carburized
fatigue specimens. Comparison of steel from
different production routes and producers
through fatigue testing was then performed
to get a deeper understanding of the correla-
tion between material cleanliness and fatigue
performance [3].
Figure 12 shows an example Figure 11: Surface hardness of the evaluated steel grades Results of Fatigue Testing.
of the staircase method for rotating bend-
ing testing, with a step size of 25 MPa and
run-out at 10 million load cycles. For better
statistics however, a larger number of samples
could be tested.
In Figure 13, the summarized results from
the rotating bending fatigue testing are pre-
sented. The fatigue limit for each material is
derived from the results from the RBF test-
ing, with a 95 percent confidence interval.
Despite the fact that all steels tested are
of similar type, prepared in the same way,
with a similar surface hardness and hardness
profile (although as shown in Figure 10,
Steel 2 has a lower surface hardness than
other samples), the fatigue limit varies quite
substantially. Steels 1–3 have a significantly
higher fatigue limit than Steel 4, and as
Figure 14 shows, the average inclusion size
initiating fatigue failure is much larger in Figure 12: Stair case method as performed on Steel 1
Steel 4 than in Steels 1–3. The difference
in fatigue limit was made evident in a series STEEL CLEANLINESS MICRO-INCLUSION RATING
production application, where Steel 4 was The cleanliness of the investigated steels was Micro-inclusion rating according to ASTM
initially validated for use, to then be changed analyzed in three different ways. First, a tra- E45, method D [4] has been used to deter-
to steel with a higher cleanliness, due to ditional micro-inclusion rating method was mine micro-cleanliness.
fatigue failures caused by inclusions. Average used, ASTM E45. Second, automated SEM As Table 2 shows, the micro-inclusion rat-
size of inclusion that initiated Fatigue Limit was used, and finally, ultrasonic immersion ing gives a very poor indication of the material
(MPa) the fatigue failure (μm). testing was performed. cleanliness, and based solely on this data, it is

Figure 13: Results of rotating bending fatigue testing. Figure 14: Average size of inclusions that initiated the fatigue failures.

34 gearsolutions.com
 Table 2: Results from ASTM E45 micro-inclusion rating.

Figure 15: Sample preparation for SEM evaluation, cut

from the center of the bar.
Table 3: Results from SEM evaluation.

Table 4: Results from ultrasonic evaluation.

Figure 16: Sample setup for SEM evaluation.

very difficult to come to any conclusions regard-

ing what to expect from material performance.

SEM EVALUATION
For automated SEM evaluation, a sample was
cut out from the center of the bar according
to Figure 15, then ground and polished and
set up according to Figure 16.
An example of the measured hardness pro-
file as seen in Figure 10, and the surface
hardness of the tested samples, can be seen
in Figure 11.
The investigated area is approximately
3,000 mm 2 , and only inclusions larger than
10 μm have been detected. A simple approach
is used to assess tested material: a total
number of defects larger than
10 μm per
3,000 mm2 as well as the longest, or largest,
inclusion. In Table 3, the results of the SEM
Figure 17: Example of oxide found in Steel 4.
evaluation are presented, and as can be seen,
Steels 1 to 3 have significantly fewer and testing equipment can be seen. The steel and 21 in the form of C-Scans. The ultrasonic
smaller inclusions in the examined area than sample is placed in a tank filled with water, cleanliness evaluations reveal that there is a
Steel 4. Figure 17 shows an example of oxides and the testing is carried out by scanning the dramatic difference in macroscopic cleanli-
present in Steel 4. ultrasonic transducer over the sample, with a ness between the steels tested.
specified distance and step size of 0.25 mm. Results from the ultrasonic inspection
ULTRASONIC EVALUATION A 10 MHz ultrasonic transducer was used can be found in Table 4. For the evalua-
Ultrasonic evaluation has a major advan- and calibrated so a 100 percent reflection corre- tion of inclusion content in the inspected
tage compared to other methods used to sponds to a ∅0.20 mm flat bottom hole (FBH). area, a more stringent specification has been
determine steel cleanliness, namely that with Two samples with a length of 200 mm developed, compared to the standards cur-
this technique, a volume of steel is examined (Figure 19) from the different steels were eval- rently available, such as the SEP 1927 [5].
instead of an area. In Figure 18, the ultrasonic uated, and the results are shown in Figures 20 This specification has been applied in this
JANUARY  2018 35
Figure 18: Ultrasonic immersion testing equipment. Figure 19: Sample geometry for ultrasonic evaluation.

investigation, and the results are presented as

both a weighted number per kg as well as the
number of defects larger than 0.20 mm FBH.
Table 4 clearly indicates that the steels
tested have a varying degree of macroscopic
cleanliness, where Steels 1 to 3 differ from
Steel 4.

DISCUSSION AND CONCLUSIONS

The aim of this paper was to highlight the
correlation between steel cleanliness and
expected fatigue performance, based on
sampling in the transverse direction, i.e.,
the most critical loading direction for a
gear blank. It was also to make apparent
the weakness in some of the commonly used
cleanliness rating methods. Micro-inclusion
rating, such as ASTM E45 on its own, gives
very little information about the material,
due to the small area examined. SEM evalu-
ation generally covers a larger area and gives
a better picture of the size and type of Figure 20: Typical results from the ultrasonic evaluation of Steels 1-3.
inclusions found in the material. Ultrasonic generally not enough to verify fatigue perfor- between clean and ultra clean steels. Whereas
immersion testing, where a larger volume is mance. A combination of micro- and macro- the method works very well for conventional
inspected, provides good data from which inclusion assessment techniques, suited to steels, a higher frequency, such as 25 MHz,
assumptions of material performance can today’s cleaner steels such as 10 MHz ultra- might instead be used for cleaner steels.
be drawn. Rotating bending fatigue testing, sonic immersion testing, are being imple- As the investigation shows, steels with a
which most steel producers use for process mented as standard practice at many global higher cleanliness level — that is, less detri-
and product development, verifies that steel automotive OEMs and transmission suppli- mental defects in the loaded volume — give
cleanliness does have an impact on fatigue ers, and it is inspection that most steel suppli- a higher performance level. These results
performance. For applications such as gears, ers can perform in-house on already-existing correspond well to component testing done
where the loaded direction after forging equipment. Taking care in the writing of on gears [6] and can therefore be considered
is quite seldom the longitudinal direction, material specifications as well as making use a relevant method of testing for expected
investigating the transverse direction of steel of state-of-the-art technology gives a much material performance. 
bars provides much more relevant informa- more relevant picture of what to expect from
tion about what can be expected from mate- your material. REFERENCES:
rial performance. As an additional comment, 10 MHz ultra- 1. Ölund, P., 2007, “TB023-2007
However, for series production, using only sonic immersion testing might not be a sensi- Replacing blue fracture testing accord-
one of the cleanliness rating methods above is tive enough method to be able to distinguish ing to ISO 3763 with Ovako 10MHz
36 gearsolutions.com
 immersion ultrasonic test-
ing,” Ovako, Hofors 

2. Eriksson, K., 2015, “Fatigue
testing of 236F, MI-2015-
236,” Ovako, Hofors 

3. Erik sson, K ., 2016,
“TBL028-2016 Fatigue test-
ing 152D and comp. CC,”,
Ovako, Hofors 

4. ASTM, 2013, “Standard Test
Methods for Determining the
Inclusion Content of Steel”,
ASTM E45-13 

5. DIN, 2010, “Ultrasonic
immersion testing method
of determining the mac-
roscopic cleanliness rate of
rolled or forged steel bars,”
SEP 1927:2010-08 

6. Wallin, K., 2014, “Internal
defects in case hardened gears
and its influence on fatigue
life,” 5th Bodycote/AGA Heat
treatment seminar, Sweden Figure 21: Results from the ultrasonic evaluation of Steel 4.

ABOUT THE AUTHORS: Joakim Fagerlund, MSc, and Lily Kamjou, MSc, are with Ovako AB. Learn more at www.ovako.com. This paper copyright ©
2017, American Gear Manufacturers Association (AGMA), ISBN: 978-1-55589-664-5 (17FTM15). The statements and opinions contained herein are
those of the author and should not be construed as an official action or opinion of the AGMA.

JANUARY  2018 37
38 gearsolutions.com
Advanced Thermal Processing
for Enhanced Gear Tribology
TriboNite technology can help improve gear performance by combining
the well-known advantages of nitriding with the superior tribological
performance profile of solid lubricant coatings.
By Boris Zhmud, Johan Blomkvist, and Mikael Fallström
ABSTRACT
Vast empirical knowledge accumulated over centuries, in
conjunction with recent advances in the areas of material
science, tribology, and big data analysis, have allowed
significant progress in gear design. Still, gears sometimes
fail. Gear tooth flanks are most vulnerable to damage
under tribological stress. Gear material, machining, and
finishing methods, lubricant, and end use are all impor-
tant factors both for the early life running-in behavior as
well as lifelong performance.
Tribolayers formed on tooth flanks due to interaction
with common EP/AW additives, such as sulfurized ole-
fins, are known to be important for ensuring adequate
surface integrity during gear operation, especially when
gear sets start or stop, invoking boundary lubrication.
Scoring and pitting are two common lubricant-related
failures, which can be remedied by proper additive selec-
tion. Unfortunately, as performance requirements are being
constantly pushed to the edge, this increases user depen-
dency on specific lubricant types with tight specifications.
Nitriding is another efficient way to increase wear and
scuffing resistance of gears, thus minimizing dependence
on the lubricant’s properties. Nitrided gears are common
in performance-critical applications such as motor racing.
In this paper, we present a new technology that bridges
the gap of opportunities between thermal processing and
lubricant design. It’s called a “hybrid thermal processing
and coating technology,” or TriboNite® [1]. This technol-
ogy combines the well-known advantages of nitriding
with the superior tribological performance profile of
solid lubricant coatings. Similar to plasma nitriding, the
TriboNite process leads to minimal distortion of treated
gears, eliminating the need to grind the tooth form
afterwards. TriboNite treated gears produce less friction,
exhibit higher resistance to bending and rolling fatigue,
withstand higher loads and are less sensitive to lubricant
quality than reference stock components. Various solid
lubricant layers — e.g. phosphate, borate, molybdenum
disulfide, etc. — can be used to target specific applica-
tion requirements.
1. INTRODUCTION
Nitriding is a heat-treating process that diffuses nitrogen
into the surface of a metal to create a case hardened surface.
Nitriding is most commonly used on low-carbon, low-alloy
steels. In recent years, however, higher-alloyed steels have
also been nitrided, with advantageous results.
The primary nitriding methods used today are gas
nitriding, salt bath nitriding, and plasma nitriding, which
are named after the medium used to donate nitrogen.
We should also mention nitrocarburizing, which is
a shallow-case variation of the gas nitriding process.
Nitrocarburizing involves thermochemical diffusion of
nitrogen, carbon, and to a very small degree, oxygen atoms
into the surface of the steel part to form a compound
layer at the surface and a diffusion layer underneath.
Nitrocarburizing is typically performed at temperatures of
550-580° C for 0.5 to 5 hours. Therefore, the method is
considered as a fast method compared to regular nitriding.
The surface hardness that can be achieved after nitrocar-
burizing ranges from 350-1,200 HV and depends on the
type of material and process parameters that are used [2].
Nitriding imparts a high surface hardness that improves
resistance to wear, scuffing, galling, and seizure. Fatigue
strength is increased mainly by the development of sur-
face compressive stresses. Nitriding also increases the
resistance of the steel against hardness loss and plastic
deformation under load at elevated temperatures.
Nitriding is typically performed at temperatures
between 500° to 550° C, and is therefore followed by a
cooling or quenching step in which the steel product is
cooled down. Quenching oils are designed for rapid and
better controlled cooling. Fast quenching after nitrid-
ing will increase the solution hardening effect from the
entrapped nitrogen, but this effect is proportionally small
compared to the precipitation hardening effect due to
hard nitrides formed from alloying elements and nitrogen
in the steel surface. Alloying elements such as Cr, Al, V,
Ti, and Mo form hard nitrides in steel during nitriding,
and the level of such alloying elements in the steel has a
huge impact on the nitriding result in terms of hardness,
wear resistance and fatigue strength.
Nitriding is most commonly carried out on pre-hardened
alloy steels. The most common nitriding steels are SAE-
AISI 4140, 4340, 6140, 7140, and 8740. The temperature
of the process is below the tempering temperature of the
steels being processed. Hence there is little or no distortion,
only about 10 μm growth due to the nitrogen diffusion
into the part. The most common applications are gearing.
Nitrided gears are used in performance-critical applica-
tions when maximum component endurance is required.
Nitrided gears can be found in the drivetrain of trucks
and racing cars and in rotary gear pumps, as well as in
special purpose gear units for the energy, petroleum,
JANUARY  2018 39
chemical, and gas industries. Nitrided gears components have been nitrocarburized at Figure 3 shows the results of compositional
exhibit higher resistance to bending and roll- 580° C for 1.5 hours. The compound layer — in-depth profiling of the surface layer by AES.
ing fatigue, which can be attributed to the marked by red bars — and, to some extent, As one can see, the solid lubricant is localized
existence of compressive stresses within the the diffusion layer can be distinguished in the within the 1 micron thick topmost layer.
diffusion zone. Also, they show little wear up images. The bright layer at the top of each
to a certain critical load, at which surface fail- image is an aluminum foil that is used to Tribological performance
ure occurs, but tend to crush badly and suffer protect the surface under the sample prepara- i. Reciprocating friction and wear test.
severe pitting when this load is exceeded [3]. tion. The black layer between the foil and the 100Cr6 steel ball was rubbed against
TriboNite belongs to the category of ther- compound layer is the solid lubricant coating TriboNite® treated SS2172 discs. As com-
mal-processing and coating (TP&C) process- and iron oxide combined. pared to regular case carburized samples,
es jointly developed by ANS and Bodycote.
TriboNite process uses a reactive quench oil
concept whereby a solid lubricant layer is
created at the surface of nitrided parts dur-
ing the quenching step. This allows further
reduction in friction and wear, better resis-
tance to high shock loads, improved scuffing
resistance, and improved corrosion protection
of treated parts.

2. EXPERIMENTS
Friction, wear, and scuffing load measure-
ments were carried out using discs (SS2172),
rods (SS0727), and standard “A” profile gears
(20MnCr5, carburized) meeting the specifi-
cations of ASTM D 4998-95 and 5182-97
tests. As reference, regular case hardened (car-
burized) and nitrocarburized components of
varying surface roughness — ranging from
Ra 0.5 μm down to 0.05 μm — were used.
Tribological performance was evaluated both
for symmetrical and asymmetrical pairs, includ-
ing standard pinion — standard gear, standard
pinion — TriboNite gear and TriboNite pinion
— TriboNite gear back-to-back combinations.
As lubricants, a synthetic SAE 75W-90 API Figure 2: Fracture SEM images of the surface layer of TriboNite-treated components: (a) and (b) - steel rods made
of SS0727; (c) and (d) - steel discs made of SS2172.
GL-5 gear oil, a viscosity matched SAE 75W-90
additive-free oil, and a dual-clutch transmission
fluid were used. Surface chemical analysis of
components in the study was carried out using
Auger Electron Spectroscopy (AES) and surface
layer morphology was studied by fracture SEM.

3. RESULTS
Surface layer morphology and composition
Figure 2 shows cross sections of the surface
layer of TriboNite-treated components. The

Figure 1: The surface layer morphology of TriboNite-

treated parts. Figure 3: In-depth elemental profiling of surface layer composition by AES.

40 gearsolutions.com
Figure 4: Effect of the TriboNite treatment on friction and wear in a lubricated
contact. Linear reciprocating friction and wear test similar to ASTM G133 was used
with the following test conditions: 10 mm 100Cr6 steel ball, 1 cm stroke, 20 N load, 1
Hz frequency. Wear loss was quantified for the ball only.
TriboNite treated surfaces demonstrate significantly reduced
wear levels both in fully formulated API GL-5 gear oils and in
viscosity matched additive-free oils, see Figure 4.
ii. FZG back-to-back gear test. The standard FZG test A/8,3/90 is
widely used for the evaluation of the scuffing properties of indus-
trial gear oils. Automotive gear oils of GL-4 level can be tested in
the step test A10/16.6R/90, axle oils of GL-5 level in the shock
test S-A10/16.6R/90 [4], and usually will show no scuffing in the
standard test. For the purpose of the present study, the standard test
has been adapted to evaluate the effect on the scuffing properties of
gear surface treatment instead of the EP/AW performance of the oil.
For that purpose, a few standard “A” type gear sets were treated by
using the TriboNite process, still a few gear sets were isotropically
finished to Ra ca 0.03 um, and still a few were used “as they are”
to serve as a natural reference. It should be noted that nitriding of
carburized parts is not a practically meaningful application scenario,
and it was used for research purposes only. One extra measurement
(marked “TP&C1/2”) was also carried out where a TriboNite treated
24-teeth gear was put in contact with a standard carburized 16-teeth
pinion. All the aforesaid types of gear sets were tested for the scuffing
performance in a fully formulated SAE 75W-90 API GL-5 gear oil
and a viscosity matched additive free oil. The results are presented
in Figure 5. When the additive free oil is used, both isotropically
finished and reference gear sets reveal scuffing quite early, already
at A/8.3/90 load stages 4 to 6. However, with the fully formulated
API GL-5 oil, no scuffing occurs even at the highest load stage 12.
The gear sets featuring the TriboNite™ treatment showed no scuffing
no matter which oil was used, see Figure 5.
In a more aggressive A10/16.6R/90 test setup, TriboNite treated
gears have exhibited higher scuffing resistance and reduced wear in
combination with dual-clutch transmission (DCT) fluids. These
results are not unexpected: as compared to SAE 75W-90 API GL-5
ABOUT THE AUTHORS: Boris Zhmud, Ph.D., FRSC (boris.zhmud@appliednanosurfaces.com), is the CTO and Johan Blomkvist, M.Sc., is the
development engineer at Applied Nano Surfaces Sweden AB, Uppsala, Sweden. Mikael Fallström, M.Sc., is the technical director at Bodycote
Värmebehandling AB, Alvsjö, Sweden. Learn more at www.appliednanosurfaces.com and www.bodycote.com, or by contacting Andreas Waller at
andreas.waller@appliednanosurfaces.com. This is a revised version of the paper [1] presented at the International Conference on Gear Production,
Sep. 13-15, 2017, in Munich, Germany.
Figure 5: Effect of the TriboNite treatment on scuffing performance measured using
the FZG A/8,3/90 back-to-back gear test rig.
axle lubricants, DCT fluids have both lower viscosity (7 cSt at 100C
for a typical DCT fluid vs 16 cSt for a typical SAE 75W-90 gear oil)
and lower EP/AW additive level (0.25 wt.% S for DCT fluid vs ca
2.5 wt.% S for API GL-5 oil).
Furthermore, notwithstanding the lubricant type, the TriboNite
treated gear sets showed invariably lower oil sump temperature,
indicating reduced friction during the test. Therefore, it is believed
that TriboNite effectively reduces dependency on the EP/AW additive
package. The benefits of TriboNite treatment can likely be further
boosted by optimizing gear metallurgy, surface finish, and the back-
ground heat treatment process.
4. CONCLUSIONS
TriboNite thermal processing and coating technology combines the
well-known advantages of nitriding with the superior tribological
performance profile of solid lubricant coatings. TriboNite-treated
gears produce less friction, exhibit higher resistance to bending and
rolling fatigue, withstand higher loads and are less sensitive to lubri-
cant quality than reference stock components. 
REFERENCES:
1. Zhmud, B., Blomkvist, J., Fallström, M., An Advanced Thermal
Processing & Coating Process for Enhancing Gear Tribology,
in Proc. Int. Conf. Gear Production, Sep. 13-15, 2017, Munich,
Germany.
2. Troel, E., Kristoffersen, H., Olsson, P., et al. Stål och värmebe-
handling - En handbok. 2015. Available from: http://14494.shop.
textalk.se/bocker/process-och-produktion/varmebehandling/
staloch-varmebehandling-en-handbok
3. Davis, J.R. Gear Materials, Properties and Manufacture, ASM
International, 2005.
4. Hoehn, B.-R., Oster, P., Tobie, T., Michaelis, K. Goriva i Maziva,
47 (2008) 129-152.
JANUARY  2018 41
There are several carbon-based coatings available that provide a unique combination of
extreme surface hardness, low friction coefficient and anti-corrosion properties from
global coating provider Oerlikon Balzers.

42 gearsolutions.com
Extending gear life
in demanding applications
Specialized PVD coatings increase the surface hardness and durability of gears,
thereby increasing their lifespan under high-load conditions.
By Jeff Elliott
ALTHOUGH GEARS AND OTHER PRECISION COM-
ponents are generally made of hardened steel or metal
alloys, those used in high load applications still can fail
due to excessive wear, surface fatigue, pitting, galling,
and corrosion. This is exacerbated in applications with
metal-to-metal interaction, repetitive friction at high
speeds or where little to no lubrication is present. Other
factors include the presence of contaminants, the prevail-
ing service temperatures, the loads applied, and loading
modes such as sliding, rolling, oscillating, and pulsating.
To address this problem, product engineers and com-
ponent manufacturers often turn to specialized PVD
(physical vapor deposition) coatings that can be applied
in thicknesses of 0.5 to 4 micrometers to further harden
the surface of these parts. By applying coatings optimized
for these types of punishing environments, components
benefit from increased surface hardness and a much lower
coefficient of friction. As a result, these critical parts do
not have to be replaced as frequently, if at all, reducing
maintenance and unplanned downtime while improving
machinery performance.
Today, these coated components are used for a variety
of applications from performance automotive and rac-
ing to wind-turbine shaft bearings and planetary gears;
stainless steel cutting blades and piston pumps for food
processing; and sliding components in filling and bot-
tling operations. The coatings are also a proven technique
for upgrading critical rotating parts in hydraulic drives,
pumps, and valves.
the surface of a ferrous metal and oxidizing salts. After a
post-treatment with oil, the surface provides protection
against corrosion, improved lubricity and prevents galling
during metal-to-metal interactions. However, black oxide
is not durable and can be worn away quickly in repetitive,
high load applications.
PTFE, another popular coating alternative, is known for
its low coefficient of friction but is not recommended for
high load applications where it, too, can wear away. Hard
chrome and chemical nickel plating are often specified
as well to provide protection against wear and corrosion.
Although hard chrome is suitable for components that
experience abrasive wear, microcracking inherent to the
process limits its use against corrosion. Although this can be
addressed with thin coatings that increase surface hardness,
these solutions only offer limited wear resistance. Chemical
nickel can be applied over a range of hardnesses. However,
the maximum is only 600 HV (Vickers Pyramid Number).
Concerns over polluting compounds, emissions, or
residues are also associated with these plating techniques.
SPECIALIZED PVD COATINGS
Physical vapor deposition (PVD)  describes a variety of
vacuum deposition methods that can be used to produce
thin coatings. PVD is typically used to coat components
at relatively low coating temperatures of 200° to 500° C.
These temperatures are ideal because they are below the
tempering temperature of steels so as to avoid altering the
fundamental material properties.

HARDENED COMPONENTS
Many components are not coated at all.
Instead, these parts are often made of heat-
treated, nitrided, or case-hardened steels,
along with durable high performance mate-
rials such as titanium or nickel based alloys.
Even those used in high-load, high-wear
applications are subject to wear and prema-
ture failure under poor lubrication. Some
industries allow no lubrication at all, such as
cryogenic and vacuum systems, clean rooms,
food, and pharmaceutical equipment. When
this is the case, engineers often turn to a vari-
ety of coating, plating, or nitriding options
to modify the surface to improve wear and
corrosion resistance.
Examples include coating the parts with
black oxide. Black oxide is a coating produced Today, these coated components are used for a variety of applications from performance
by a chemical reaction between the iron on automotive and racing to wind turbine shaft bearings and planetary gears.

JANUARY  2018 43
By applying coatings optimized for these types of punishing environments, components benefit from increased surface hardness and a much lower coefficient of friction.
(Courtesy: Oerlikon)
Fortunately there are several carbon-based
coatings available that provide a unique
combination of extreme surface hardness,
low-friction coefficient, and anti-corrosion
properties such as those provided by global
coating provider Oerlikon Balzers.
According to Manfred Berger, market
segment manager of General Engineering
Components for Oerlikon Balzers, the com-
pany’s Balinit C coating is a WC/C ductile
carbide carbon coating that is highly resistant
to adhesive wear (scuffing) in particular. It
44 gearsolutions.com
has a high load-bearing capacity even under
conditions of deficient lubrication or dry
contact. Due to its low friction coefficient, it
acts to reduce pitting and fretting corrosion.
Another example is the Balinit DLC coat-
ing, a metal-free, carbon-based coating that is
even more durable. Applied through plasma-
assisted chemical vapor deposition (PACVD),
this coating is designed for more severe wear
conditions and high relative sliding speeds
to protect against abrasion, scuffing, and
cold welding.
These and other coatings within the Balinit
family tailored to specific requirements can
be applied to a variety of case-hardened or
tempered steels, austenitic stainless steel as
well as nickel, titanium, copper, magnesium,
and aluminum alloys.
“These materials provide an excellent com-
bination of low coefficient of friction like
PTFE, but with the hardness of a ceramic,”
Berger said.
The coatings also have the advantage
of being thin, typically 0.5 to 4 μm. This
feature, in conjunction with close toleranc- ability and performance by reducing wear on thickness and hardness, properties such as struc-
ing, means the component retains its form, both the worm and the bronze gear. ture, chemical and temperature resistance, and
fit, and dimensions after coating without the adhesion can be precisely controlled.
need for re-machining. CUSTOMIZED SOLUTIONS In most cases, no alteration of the formula
Gears experience wear conditions. The In addition to designing and manufacturing for the coatings is required, as it is already opti-
PVD coating significantly reduces scuffing PVD coating equipment, Oerlikon Balzers mized for high load, high friction environments.
and pitting in gears. In fact, Balinit C has offers coating services at more than 140 coat- “I find engineers are most surprised about
been shown to quadruple the service life of ing centers worldwide, including 16 locations two factors when learning about these spe-
high-speed gears. The standard FZG C test throughout the United States. cialized PVD coatings,” Berger said. “First,
shows that the fatigue strength is increased According to Florian Rovere, director of sales that the coating can be applied in a thickness
by 10-15 percent over case-hardened but for Precision Components in North America, as low as 0.5 or 1 micrometers. The other is
uncoated gears. In the test, the failure the company has the research and development that these coatings can last the lifetime of
criterion for gear-service life was defined capabilities to tailor coating solutions to meet the machine or systems it is in, despite the
as single-tooth wear of 4 percent due to unique requirements. In addition to coating difficult operating conditions.” 
pitting. The main factors in these improved
figures were the lower local surface pres-
sure (Hertzian pressure), which resulted
from reduced friction in the rolling contact,
and the superior running-in behavior of
Balinit C.
High Tech is our Business
Coatings can also benefit worm gears,
where lubrication is not always enough to
protect helical-gear transmissions against fric- ALD is a leader in vacuum
tion and wear. The sliding motion and the process technology and Heat
force between the worm and gear faces make treatment services.
it difficult for a lubricant film to form. For
this reason, the gear is most often made of LEADERS IN THE
bronze in order to avoid scuffing. CONTROL OF DISTORTION
In service, however, the teeth of the bronze ALD Thermal Treatment, Inc.
gear wear away quickly, and the gear must be + Low Pressure Carburizing
realigned or replaced. Coating the steel worm + High pressure gas quenching
with a carbon-based coating can improve reli- + Gas Nitriding
+ Ferritic Nitro-Carburizing
+ Plasma Carburizing
ABOUT THE AUTHOR: Jeff Elliott is a technical + Normalizing
writer based in Torrance, California. For + Hardening
more information about coating solutions for + Annealing
components go to www.oerlikon.com/balzers.
+ Brazing
+ Cryogenic Treatments
+ Engineering services and
process development
+ Prototype and trials

Global Service Centers

Enrique Lopez – Sales and Marketing
 Limbach-Oberfrohna Email: sales@aldtt.net
Germany Phone +1 (810) 357-0685
 Port Huron, Michigan
ALD Thermal Treatment, Inc.
USA 2656 24th Street
 Ramos Arizpe, Coahuila Port Huron, MI 48060, USA
Mexico

www.aldtt.net

ALD is a subsidiary of AMG Advanced Metallurgical Group N.V.

Balinit C has been shown to quadruple the service life of
high-speed gears.

JANUARY  2018 45
(Photos courtesy: Klingelnberg)

46 gearsolutions.com
Closed Loop Machining
of Cylindrical Gears
Looking to raise the quality and accuracy of your gearing? Consider Closed Loop
design and manufacturing, which has done away with the error-prone data
transfer from the measuring sheet.
By Dr. Markus Brumm

LEONHARD EULER’S 1760 INVENTION OF MAKING requires a description of the gear geometry based on the
cylindrical gears with an involute profile was the begin- tool profile and the manufacturing kinematics. For this
ning of a success story. As a tooth profile, the involute has
reason, Klingelnberg has been applying the core idea
many advantages that are still being used by engineers to of Industry 4.0 to bevel gear manufacturing since the
design high-performance transmissions that even func- early 1990s and has created a cyber-physical system that
tion under high loads and the consequential deformation produces digital images of the gear along the entire value
of the shaft bearing system. creation chain, therefore making it possible to introduce
However, the convention of designing cylindrical gears objective quality gates.
with an involute profile also represents an obstacle for Figure 1 shows the value creation chain of a bevel gear
innovative solutions. For many years, the CAD-CAM set. It starts with the engineering of the gearing, which
process has been state-of-the-art in the metal-cutting also includes the material specification. The gearing is
production of general components. The workpiece is first first optimized in order to comply with the required speci-
described as a 3D model, and tools are then selected and fication in a given environment consisting of bearings,
NC files generated in the CAM process that follows. The gear housing, and operating conditions. The result is a
digitally described workpiece is then produced on the digital twin of the bevel gear, which does not just contain
machining tool on the basis of these files. This principle all of its geometrical information; due to the particular
cannot be used with cutting machines because the gear nature of a bevel gear’s description, all of the information
is not described as a 3D model. about the tool and the description of the manufacturing
Based on the theory of involutes and other curves for movement of a virtual cutting machine is present for
gear drives proposed by Euler, a gear is always described both soft machining and hard machining. This data is
by the geometry of the tool edge and a relative motion automatically supplied by Klingelnberg’s KIMoS program
between this tool and the gear to be produced. Even system, and represents the digital backbone of all stages
though we now have five-axis machining principles capa- of manufacturing. Horizontal integration of all machines
ble of producing gears, this particular gear description is and program systems involved in the process has been
always the basis, and therefore the reason for the special realized in this way, whereby the central database contains
nature of the cutting machine species. the digital images and the geometry-determining tech-
nological parameters for every stage of manufacturing.
LEARNING FROM BEVEL GEARING Unlike bevel gear manufacturing, which is based on
The geometry of bevel gears is not based on the involute, a database system, paper is the dominant data medium
but on the octoid. A clear description of the flank profile in cylindrical gear manufacturing. This simple and

Figure 1: Value creation chain of a bevel gear set.

JANUARY  2018 47
seemingly unambiguous description means
that toothing data still has to be manually
entered into cutting machines and measuring
devices multiple times. The many manufac-
turers of cutting machines and measuring
devices have not been able to agree on inter-
faces for data communication to date.
CLOSING THE LOOP
The seemingly simple description of involute
gearing leads to a false sense of security.
Ultimately, mistakes occur during manual
data transfer. Not least because the DIN, VDI,
and ISO standards can differ in key points.
Jobs always ship within a week —
DEFINITELY no complaints! Thank you
all for doing such an awesome job!
Keep up the great work!
Gear Manufacturer / Southeast USA
1.800.569.1420
www.McInnesRolledRings.com
533 E 12TH STREET • ERIE, PA 16511
48 gearsolutions.com
One example is the sign for the lead angle
deviation fhβ, which can have opposing signs.
The value of the respective parameters also
depends on the underlying evaluation section,
meaning that a parameter is only unambigu-
ous if the evaluation section and the applied
directive are specified. Misunderstandings
and erroneous entries are commonplace due
to this heterogeneity. Many users counter
these errors by defining additional in-house
conventions. Dealing with the error suscep-
tibility of the antiquated data transfer from
paper with additional processes unnecessarily
complicates the transfer of the measuring
Figure 2: Closed Loop 1.0.
results to cutting machines. Klingelnberg
has therefore developed a Closed Loop for
cylindrical gears based on the Closed Loop
that already exists for bevel gears. The aim
was to realize a robust and fault-resistant
transfer of the gearing deviations determined
on a Klingelnberg measuring device to pro-
duction machinery.
To do this, it was necessary to clearly char-
acterize the information on the measuring
sheet and to transfer it via a general and open
interface. Closed Loop for cylindrical gears
uses the Gear Data Exchange (GDE) format.
This format, which was defined in VDI/
VDE guideline 2610, was chosen to ensure
that measuring results could be transferred to
the cutting machines of every manufacturer.
The measuring sheet is incorporated in the
production network in *.xml format.
The measuring procedure is carried out as
shown in Figure 2. The component that is
manufactured on a cutting machine is mea-
sured on a Klingelnberg measuring machine.
When the measurement is complete, the digi-
tal measuring sheet is saved on the server.
From there, it is transferred to the cutting
machine, which must have an appropriate
import function.
The Klingelnberg Gear Production
machine software already has the function-
ality for reading in the digital measuring
sheet. In the practical implementation of
Closed Loop for cylindrical gears, there are
a number of points that must also be taken
into consideration in addition to those already
mentioned. In many cases, customers have
several measuring devices and several cut-
ting machines. This makes it necessary to
identify which digital measuring sheet must
be assigned to which process and which
machine. Before the measurement takes
place, the measurement task is assigned to a
production order by entering the order num-
ber and the serial number. This information
was sometimes also entered to designate the
measuring sheet and is stored in the digital
measuring sheet and the file name.
The cutting machine on the shop floor there-
fore recognizes associated measuring results.
The system actively notifies the operator that
new measuring results are available for the cur-
rent production order. During production, the
machine operator can identify which gearing
parameters need to be corrected based on a Production network with multiple cutting machines and measuring devices.
diagram. The parameters are color-coded and
displayed for this purpose in the tolerance field with the error-prone data transfer from the way. But this is just the beginning. The big-
on the machine control panel. A new machine measuring sheet. ger challenges exist in the manufacture of
setting is calculated at the touch of a button The current version can be used for exter- non-involute gearing or the production of
when the next component change takes place. nal and internal gearing. The system also topological modifications. The Klingelnberg
The first step in introducing a digital pro- recognizes inverted measurements compared Closed Loop for cylindrical gears is just at the
duction system for cylindrical gears has there- with the clamping in the machine, and trans- beginning of development into an Industry
fore been taken. Closed Loop has done away fers the measuring results in a context-related 4.0-compliant production system. 

ABOUT THE AUTHOR: Dr. Markus Brumm is director of the Cylindrical Gear Division at Klingelnberg. Learn more at www.klingelnberg.com.

Pressure angle and base tangent length correction in gear production.

JANUARY  2018 49
 PRODUCT NEW PRODUCTS, TRENDS,

SHOWCASE SERVICES, AND DEVELOPMENTS

FOREST CITY GEAR ADDS

VERSATILE GRINDER TO LINE
Forest City Gear has expanded its capabilities for the hard finish-
ing of smaller diameter gears with particularly tight ID and length
tolerances with the addition of a Usach 100-T4 ID/OD grinder with
4-station turret.
While the new Usach can accommodate parts with diameters as
large as 450 mm (17.71”), its ability to deliver exceptional grinding
performance for gears with smaller diameters made from difficult-to-
machine hard materials made it ideal for the types of projects Forest
City Gear specializes in, according to Forest City Gear Director of
Operations Jared Lyford.
“Where in the past we might have outsourced this work, we’re now The Usach features a 4-station turret to speed changeover between three ID grinding
able to take on even the most challenging ID  grinding configurations spindles, an OD grinding spindle, and a probe unit for in-process inspection of axial
in-house and maintain tighter control of the process,” Lyford said. length, roundness, feature size, and other critical part characteristics. (Courtesy:
Forest City Gear)
“It’s an amazingly versatile, highly productive machine.”
The Usach features a 4-station turret to speed changeover between Since 1955, Roscoe, Illinois-based, family-owned Forest City Gear
three ID grinding spindles, an OD grinding spindle, and a probe has been one of the gear industry’s leading sources for the develop-
unit for in-process inspection of axial length, roundness, feature ment, manufacture, and inspection of the highest quality gears,
size, and other critical part characteristics. An on-board rotary for use in applications that include medical devices, motorcycles,
diamond dresser enables Forest City Gear to use dressable CBN airplanes, automation, and even the Mars Curiosity Rover. 
grinding wheels for profile grinding of radius angles and other
special features. FOR MORE INFORMATION: www.forestcitygear.com

NEW RANGE OF GO/NO-GO GAGES

AVAILABLE FROM SLATER TOOLS
Slater Tools introduces its new and comprehensive product line of
Go/No-Go gage sets for customer-specific applications. The full
range of gages are designed and engineered precisely to inspect
parts for machining process variations such as form size, twist,
and tool wear.
Ideal for use with Slater Tools rotary broaches, these gages are
held to extremely tight tolerances, within 0.0002 inches (0.005 mm).
They are produced from oil hardened M2 high-speed steel and can
be custom made to any shape or size to fit custom needs.
All gages are offered for numerous shapes, either as full-form
composite, sector, or progressive forms. Both plug and ring gages are
offered for checking internal or external forms. The company offers
long-form gage certification upon request for those applications and
industries that require it.
“Our customers are facing increased demands to produce precision
parts with fast turn-around. It has always been our goal to provide
support for our customers’ success, and with the new gage line, they
have the tools they need to quickly check their parts,” said Kris
Renner, director of operations at Slater Tools.
Popular shape gages, such as hexagon and six lobe (hexalobular), are
available as standards in both inch and metric dimensions. Custom
plug and ring gages are also available with rapid turnaround times.
50 gearsolutions.com
Precision Go/No-Go Gages from Slater Tools validate
critical shape-making applications for today’s
metalworking industry. (Courtesy: Slater Tools)
Both standard and custom inspection gages are available as Go/
No-Go sets or can be purchased individually.
Slater Tools is the leading manufacturer of rotary and static broach-
es and tool holders that ensure precision and save customers time and
money with hex, square, spline, serration, and other custom-shaped
applications. Additionally, the company manufactures all Go/No-Go
form gages, a full range of screw machine tooling, and spring-loaded
male/female live centers. All products are designed, engineered, and
manufactured in Clinton Township, Michigan, using state-of-the-art
equipment and advanced techniques to provide a continuous stream
of standard and custom solutions.
FOR MORE INFORMATION: www.slatertools.com
JUNKER’S JUCAM 1S
NON-CYLINDRICAL GRINDING MACHINE
OFFERS ECONOMICAL GRINDING
OF CAM PIECES
As increasingly stringent carbon emissions regulations are being
imposed on the automotive industry, one solution to ensure compli-
ance with these regulations is with variable engine timing using cam
pieces. The JUCAM 1S from Junker specializes in the ultra-precise,
efficient grinding of cam pieces. With its leading-edge technology
and minimal downtimes, this machine maximizes economical pro-
duction.
The nerve center of the JUCAM 1S is a double workhead with
two clamping fixtures. It can be swiveled 180 degrees to a precisely
defined end position. The workpiece transfers from its initial loading
position to the grinding position using a fully automated process.
Concurrently, the second workpiece transitions from the grinding to
the discharge position, which drastically reduces downtime.
With its world-class ingenuity and design, Junker’s JUCAM 1S
enables automotive manufacturers and suppliers to achieve extremely The non-cylindrical grinding machine JUCAM 1S from Junker grinds cam pieces and
economical cam piece grinding. The Junker non-cylindrical grinding single cam packages with the utmost precision and efficiency. (Courtesy: Junker)
machine also specializes in the efficient package grinding of single
cams. Depending on the application, the grinding wheels are comprised of
When grinding cam pieces, the precise angular reference to the a carbon base body: It is lightweight, possesses vibration-damping
inner toothing is essential. Accordingly, the JUCAM 1S clamps the properties, and remains dimensionally stable even at high speeds.
cam pieces with an inner clamping mandrel. The high-quality stan- With its JUCAM 1S, Junker offers far more than just a grinding
dards demanded by the automotive industry are fulfilled by the "cam machine. The company’s performance promise includes delivery and
piece specialist” with its intelligent control system. This compensates installation of the machine as well as a fully customized grinding
automatically for material deviations or disturbing variables such process to meet the customer's wishes and production requirements.
as fluctuations in temperature, guaranteeing that all components By combining the non-cylindrical grinding of cams with the cylin-
conform to a constant standard. drical grinding of bearings, the JUCAM 1S is the complete solution
CBN, in a range of specifications, is used as an abrasive for maxi- for cam piece grinding needs.
mum repeat accuracy, extended service life, and high stock removal
performance coupled with a consistently high standard of quality. FOR MORE INFORMATION: www.junker-group.com

FLEX GRIP: ONE CLOSER, FOUR WORK HOLDING SOLUTIONS

Lexair’s new Flex Grip closers are designed for
versatility and efficiency, and they are proven
to boost productivity for a variety of machin-
ing operations including 5-axis, rotary index-
er, and stationary applications. The manual/
hydraulic closers are clamped through a screw
pump with a spring return opening. A parts
stop disk is inserted and removed from the top
to eliminate the need to remove the closer from
the mounting base. The closers can also be
equipped to operate under M-code command
for fully automated applications.
With the addition of a Hardinge 5C and
16C-tooling adapter, Flex Grip closers can be
used with Hardinge FlexC™ collets and Sure
Grip I.D. mandrels, 5C and 16C collets, as
well as 5C and 16C step chucks, providing
four working holding options in one collet.
Flex Grip closers are available in sizes of
65mm and 80mm and grip force up to 21,600
pounds at 65 lbs./ft. The collets can be custom-
fitted to nearly any application, and according
to Lexair, testing has yielded 0.0002-in. part
accuracy, with ± 0.020-in. range on part diam-
eter and a 10-second collet change.
“With the addition of these tooling adapt-
ers, the 65 and 80 mm Flex Grip closers are
some of the most versatile work holding solu-
tions of their kind,” said Steve Breslin, nation-
Designed for fourth and fifth axis, rotary indexer, and
al sales manager, Lexair. “We’ve checked all stationary applications, Lexair’s Flex Grip reduces set
the boxes: easy to setup, easy to use, excellent up times with 10-second collet change capability, and
part results.” 0.0002-in. part accuracy. (Courtesy: Lexair)

FOR MORE INFORMATION: www.Lexairinc.com

JANUARY  2018 51
ALLIED MOTION INTRODUCES KINETIMAX 42 EB
BRUSHLESS DC MOTOR WITH INTEGRATED DRIVE
Allied Motion Technologies introduces the
KinetiMax 42 EB, a 42-mm diameter outer
rotor, brushless DC motor with an integrated
drive. Extremely compact, the KinetiMax 42
has a robust bearing system capable of han-
dling high side loads. It has a minimum oper-
ating life of 20,000 hours. The KinetiMax
has an integrated speed control loop with
speed set input to adjust motor speed from
150 to 5,000 rpm.
The external rotor and iron-core stator
minimize cogging and maximize output
torque. The higher inertia of the outer rotor
design enables a smoother running motor
even at low speed. The KinetiMax 42 is
GF MACHINING SOLUTIONS’ NEW DIE SINKING EDM RATCHETS UP EFFICIENCY
GF Machining Solutions’ new FORM P
350 die sinking EDM machine features
precision-enhancing design qualities along
with several integrated technologies to
enable shops to easily enhance productiv-
ity and profitability.
A compact C-axis construction, fixed
table, and cast-iron frame offer high stabil-
ity and force reduction to help maintain
a precise spark gap between the part and
the electrode. Regardless of part weight or
dielectric volume, the FORM P 350 delivers
consistent accuracy and a best surface finish
of Ra 0.1 μm. Integrated glass scales preserve
long-term, repeatability and eliminate the
need for recalibration as well as any errors
found in traditional screw systems due to
backlash and wear.
At the heart of the machine is GF
Machining Solutions’ own high-end,
Intelligent Power Generator (IPG), one of
the world’s most powerful generators for
die-sinking EDMs. With integrated quality-
enhancing and cost-saving intelligence, the
company’s TECFORM module ensures that
the EDM process is continuously optimized
with each pulse to significantly reduce elec-
trode wear or obtain the finest finishes.
The embedded TECFORM module
allows the FORM P 350 to quickly and
safely achieve the best performance and
desired results. Segment-dedicated tech-
nology eliminates the need for the opera-
tor to adjust the generator’s parameters.
FOR MORE INFORMATION: www.gfms.com
52 gearsolutions.com
equipped as standard with thermal overload
protection with automatic recovery, and
reverse supply voltage protection.
KinetiMax 42 offers a cost-effective solu- The extremely compact KinetiMax 42 has a robust
tion for applications including smaller capacity bearing system capable of handling high side loads.
(Courtesy: Allied Motion)
pumps, fans and blowers, scanners, and similar
applications that require smooth fixed or vari- • IP54-rated protection.
able speed control. • Low EMI (complies with EN55014-1/2,
KinetiMax 42 highlights include: 61000-6-1/3).
• 70 mNm rated torque and 31 W output • Options include customized shaft, mount-
at 4,300 rpm. ing flange, leads and connector configura-
• Six-wire version with tachometer output tions, and special winding voltage rating.
(18 pulses per rev) for speed monitoring,
speed input and direction input. FOR MORE INFORMATION:
• Choice of 12 or 24 VDC winding. www.alliedmotion.com
Spark process control takes a fraction of a 3R macro tooling. A rotary tool changer
second and produces an extremely homoge- (RTC) can be added to replace the four-
neous surface finish. In combination, these position linear tool changer on the left side
features yield greater reliability, improved of the machine to increase the number of
machining efficiency, and significantly less electrodes up 160 in a very small space. The
unproductive time. FORM P 350 can also be paired with the
Equipped with GF Machining Solutions’ System 3R WorkPartner 1+ robot for unat-
breakthrough iQ (innovation + quality) tended night and weekend operation.
groundbreaking technologies to control the With X/Y/Z axes travels of 17.8” x 9.8”
erosion process of graphite and/or copper x 11.8” (350 x 250 x 300 mm), shops can
electrodes, the FORM P 350 is highly effec- efficiently machine workpieces up to 27.6”
tive at reducing costs in die sinking opera- x 18.1” x 10.8” (700 x 460 X 275 mm.) 
tions. iQ technology brings together fast
and efficient electronics capable of real time
spark characteristic analysis and adjusts
the current setting as needed for absolute
pulse efficiency. This ensures wear-free
spark erosion, high precision, extremely
efficient performance, unparalleled respect
for detail, and greater control over the cost
of the electrode.
The machine console is equipped with
the user-friendly AC FORM HMI (human
machine interface) that is based on a stan-
dard Windows® platform and offers interac-
tive graphical assistance so that all opera-
tions, such as measurement and machining
cycles, are illustrated by graphics/icons for
fast operator understanding and ease of use.
It provides simple descriptions of machining
targets, automatic selection of optimal tech-
nology and dynamic parameters adaption. The FORM P 350 comes standard with a four-position
The FORM P 350 comes standard with a linear tool changer for System 3R macro tooling.
four-position linear tool changer for System (Courtesy: GF Machining)
 MACHINERY
FEATURED SUPPLIERS
Gibbs Machinery Company – REF #102
Phone: 586-755-5353 Fax: 586-755-0304
Email: rj@gibbsmachinery.com
Website: www.gibbsmachinery.com
Havlik International Machinery, Inc. – REF #103
Phone: 519-624-2100 • Fax: 519-624-6994
Email: havlik@bellnet.ca
Website: www.havlikinternational.com
General Tool & Engineering Company - REF #107
Phone: 501-945-7111 • Fax: 501-945-7111
Email: generaltoolandengineering@hotmail.com
Midwest Gear Corporation – REF #104
Phone: 330-425-4419 • Fax: 330-425-8600
Email: sales@mwgear.com
Website: www.mwgear.com
New England Gear – REF #105
Phone: 860-223-7778 • Fax: 860-223-7776
Email: jeff@newenglandgear.com
Website: www.newenglandgear.com
Phoenix Tool & Thread Grinding – REF #106
Phone: 216-433-7008 • Fax: 216-433-7067
Email: phoenixthread@yahoo.com
Website: www.phoenixthreadgrinding.com
GEAR ACCESSORIES, PARTS & TOOLING
FELLOWS Model #10-4/10-2, All Parts Available  REF#105
Tilt Tables for 10-2/10-4, Qty 2  REF#105
GEAR HOBBERS/CUTTERS CNC
Pfauter PE150, 15MB Fanuc, Chip Conveyor, Auto Load  REF#102
Pfauter PE150, Siemens 3M, Magnetic Chip Conveyor, Oil Chiller  REF#102
Pfauter PE150, Fanuc 15, with light hob slide 8”  REF#102
Pfauter PE80, 15MB Control, Auto Load, Light Curtain  REF#102
Liebherr LC82 15M Fanuc Control, Auto Load  REF#102
Liebherr LC502, 20”, Fanuc 16im, 2007  REF#102
Liebherr LC380, 440mm W/100mm Hob, 2008  REF#102
GEAR HOBBERS/CUTTERS
TOS OFA Series Conventional Gear Hobbers, 12” & 40” Dia  REF#103
TOS OHA Series Conventional Gear Shapers, 12” & 40” Dia  REF#103
PFAUTER P1251 Hobbers s/n 25-276 and 25-277  REF#105
PFAUTER (1) RS-00 s/n 17593  REF#105
BARBER COLEMAN (1) 16-36 multi cycle s/n 4404  REF#105
Lees Bradner 7VH, 8”PD, 10” Face, , Magnetic Chip Conveyor , Hob Shift  REF#102
Lees Bradner 7VH, 8”PD, 4PD, Magnetic Chip Conveyor, Hob Shift  REF#102
Barber C. 16-15, 4” Hob, Crowning, Differential, Double Cut, 3 DP, 1977  REF#102
G & E 36H, 36”, Hi-Column, Differential, From AEM Toolroom, Excellent  REF#102
G & E Model 48HS, 48”PD, 18” Face, 2.5 DP, Hi-Column, Heavy Duty, 8” Hob REF#102
Liebherr L301, 12” Crowning, Double Cut, Differential, Hob Shift  REF#102
Liebherr L401, 16”, Differential, 2-Cut Cycle, Chip Conveyor, 7.566” Hob Dia.  REF#102
Liebherr L402, 2-Cut, Infeed, Differential, Tangential Feed, 19.3 OD W/4” Hob  REF#102
Cleveland 1886, Hi-Helix, Hob Head, Auto Hob Shift, 4-Pitch, 1975  REF#102
GEAR HOB & CUTTER SHARPENERS (INCL CNC)
TOS OHA Series CNC Gear Shapers, 12” & 40” Diameter  REF#103
TOS OFA Series CNC Gear Hobbers, 12” & 40” Diameter  REF#103
Barber Colman 10-12, Water Guards, Dresser, Index Plates  REF#102
Star 2VHS, 6”x6”, Coolant, Change Gears, REF#102
Star 4 x 4 (G691), 0-7000 Spindle Speeds, Auto Cycle, Coolant  REF#102
CONTACT GEAR SOLUTIONS AT
800-366-2185 TO LIST YOUR MACHINERY.
Barber Colman 4-4, Index Plates, Very Light Use, Excellent  REF#102
Gleason 538, 18” Shaper Blades, Makes Blades from Blanks, Light Use, Extras  REF#102
Star 2VHS, 6” x 6”, Coolant, Change Gears  REF#102
GEAR SHAPERS CNC
36” Shapers, 14” Throat Risers, 53” of Swing, Qty 3  REF#105
FELLOWS #10-4/10-2, Qty 150  REF#105
HYDROSTROKE #50-8, Qty 2  REF#105
HYDROSTROKE #20-8, Qty 5  REF#105
HYDROSTROKE #FS630-125, Qty 1  REF#105
HYDROSTROKE #FS400-90, Qty 2  REF#105
FELLOWS #20-4, Qty 6  REF#105
FELLOWS #48-8Z, Qty 1  REF#105
GEAR SHAPERS
FELLOWS #10-2, (10” Dia), 2” Face  REF#105
FELLOWS #10-4, (10” Dia), 4” Face  REF#105
FELLOWS (200) 10-4 / 10-2 Shapers  REF#105
FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/ 6 axis 16iMB Fanuc (2009)  REF#105
FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/ 6 axis 16iMB Fanuc (2009  REF#105
FELLOWS (1) #7 125A Face Gear Machine  REF#105
FELLOWS (2) #3 Face Gear Machine  REF#105
(1) 4ags with adjustable Helical Guide s/n 30634  REF#105
(1) #7 125A adjustable Helical Guide  REF#105
FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc Controller (2009)  REF#105
FELLOWS (2) Swing-away center support for 10-2 / 10-4  REF#105
FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/ 6 axis 16iMB Fanuc
(2009)  REF#105
FELLOWS (2) FS400-170 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009)  REF#105
FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009)  REF#105
FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis 21i Fanuc Controller (2009)  REF#105
FELLOWS (1) 48-8Z Shaper w/ 14” throated riser (53” of swing)  REF#105
FELLOWS (1) Horizontal Z Shaper s/n 21261  REF#105
FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB 4 axis Fanuc controller
s/n 34326  REF#105
FELLOWS (1) 36-10 Gear Shaper  REF#105
FELLOWS (1) 10x6 Horizontal Z Shaper  REF#105
FELLOWS (1) 36-6 Gear Shaper w/ 13” riser s/n 27364  REF#105
FELLOWS (1) 10-4 Shaper w/ 3” riser w/ 4 axis 21i Fanuc Controller (2009)  REF#105
All Parts for 10-4/10-2 Fellows Gear Shapers  REF#105
GEAR DEBURRING/CHAMFERING/POINTING
Cross 55 Gear Rounder, 18” Chuck, Hydraulic Unit  REF#102
Cross 65, 10” Gear Pointer, Power Cylinder, Cutter, Change Gears  REF#102
Cross 85 10” Chamfer, (2) Cutter Heads, Bevel, Spur, Helical  REF#102
Samputensili SCT3 13.7”, SM2TA 10”, (5), 2003  REF#102
Samputensili SM2TA, 10”, Max. Face Width 4”, Hyd. Work Clamping, 1983-2003  REF#102
Mitsubishi MA30 CNC, 11”PD, Fanuc Control, Powermate, 1999 (2)  REF#102
GEAR HONERS
National Broach GHG 18”, Power Stock, Crowning, Variable Speed  REF#102
Toyo T465 CNC, 160M Fanuc 5-Axis, Power Stock, Uses Fassler Tooling,  REF#102
GEAR GENERATORS
Gleason 11 Spiral Bevel, 13”, Stock Divider, Hyd. Chucking, Roughers & Finishers  REF#102
Gleason 12”, Gears, Gauges Tool Blocks  REF#102
Gleason 16 Spiral Bevel, 18”, 2-1/2 DP, Modified Roll, Chip Conveyor  REF#102
Gleason 24 Rougher, Gears, Finishing Tool Holder  REF#102
Gleason 116 Rougher & Finisher (6)  REF#102
Gleason Phoenix 175HC CNC – 1994  REF#102
Gleason 22 Rougher & Finisher (8)  REF#102
Gleason 26 Spiral Bevel, 33-36”, Mod. Roll, Stock Divider, Coolant, Change Gears  REF#102
Gleason Phoenix 450HC, Spiral Bevel, 150MB Fanuc  REF#102
Gleason 610 Combination Rougher & Finisher, 1988  REF#102
Gleason 608 & 609 Rougher & Finisher  REF#102
Gleason 645 Spiral Bevel, Helical Motion, Chip Conveyor, Variable Rate of Roll  REF#102
Gleason Cutters, 3” to 25” in stock, 1000  REF#102
GEAR GRINDERS
#27, #137, and #463 Gleason Hypoid Spiral Bevel gear grinder generating Cams
(2 full sets)  REF#105
Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing  REF#105
Reishauer NZA, 12”, Fassler Dresser, Many Extras, 1994  REF#102
Reishauer RZP, 4-8”, Auto Loading, High Production, Use in Lab  REF#102
Reishauer RZ301AS CNC, 13” Measuring System (3)  REF#102
Reishauer ZB, 27.5” PD Gears, Coolant  REF#102
Gleason 120 Curvic Coupling, 24” Max. Dia., Index Plates, Extras  REF#102
Csepel FKP-326, Fassler Dresser, Like A Hogland NZA Reishauer, Super Cond.  REF#102
National Broach SGK-24, Max. OD 31”, ID 24”, Spur & Helical, From Aircraft  REF#102
Maag SH150, 60”, Change Gears, 2-Pitch, Max. Face 23-1/2”, Navy Surplus  REF#102
ZSTZ 800 WMW Niles  REF#107
GEAR SHAVERS
Red Ring GCU 12” Crowning, 1956 to 1988 (6)  REF#102
Rex Ring GCX 24”, Crowning, 12” Cutter Head, Taper Attachment, Long Table  REF#102
Mitsubishi FB30, 12.2 CNC Fanuc, 1997  REF#102
Michigan 870, Crowning, Power Stocks, Very Light Use, Excellent  REF#102
National Broach GCY 18”, Crowning, Max. 19=1/2”, Rebuilt or Under Power  REF#102
National Broach GFF, Crowning, Heidenhein Scales, Servo Drives, 1993  REF#102
Raso Sicmat 400 CNC, Fanuc 16iM, Chip Separator, 2001  REF#102
GEAR TESTERS/CHECKERS (INCL CNC)
FELLOWS (1) RL-600 Roll Tester s/n 35814  REF#105
FELLOWS (1) 24H Lead Checker s/n 32289  REF#105
GLEASON (1) #14 Tester s/n 31907  REF#105
GLEASON (1) #6 Tester s/n 19316  REF#105
FELLOWS (1) 20 M Roller Checker  REF#105
FELLOWS (1) 20 M w/ 30” Swing Roller Checker  REF#105
FELLOWS (1) #8 Micaodex s/n 36279  REF#105
Fellows 24M Involute, Response Electronic Recorder, Hot Pen  REF#102
Fellows 36” Space Tester, Hot Pen Guaranteed  REF#102
Fellows 8M Redliner, 13 5/8”, Recorder (2)  REF#102
Gleason 6, 7-1/2” Indicator Check, Pinion .00015, Gear .00001  REF#102
Gleason 17A Running or Rebuilt Guaranteed  REF#102
Gleason 511, 20” Reconditioned in 2010 Guaranteed  REF#102
Gleason 502, 10”, Hydraulic Chucking, Automatic Backlash, Eliminator  REF#102
Gleason 513 20” Gear, 10’ Pinion Electronic Meter Reading of Sound (3)  REF#102
Gleason 515, 24”  REF#102
Gleason 520, 30”, Hyd. Chucking, Auto Splash Doors/Backlash, Eliminator  REF#102
Gleason 523, 20” Reconditioned, 2010  REF#102
Gleason 528 Cutter Inspection, Proximity Type Gage, 3.5”-25”, Conventional  REF#102
Illinois 1731-3C, Hob & Worm Lead Tester, Electronic Recorder, Master Hob  REF#102
Illinois 3412B-3C, 12” Involute with 1606 Electronic Recorder, Master Gauge  REF#102
Illinois 3824-1-3B Spline & Spur Lead Tester, Max. Centers 52”,
1606 Recorder  REF#102
Illinois 3912-3C Lead Tester, 12”, 1607 Electronic Recorder, 1980  REF#102
Klingelnberg PFS600 W/Masters, Recorder, Extras, 23.6”, 0.59-23.6”  REF#102
M&M 3015, 15” Gear Analyzer, P2 Computer Software, 12”Mag. Chuck  REF#102
GEAR THREAD & WORM, MILLERS/GRINDERS
Ex-Cell-O 36 External Thread Grinder  REF#106
Jones & Lamson 12 x 45 Automatic Thread Grinder  REF#106
Lees Bradner HT 12 x 54 Thread Miller  REF#106
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#104
Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing  REF#105
TOS SU & SUS Series Conv Lathes  REF#103
TOS SUA Series CNC Flat-Bed Lathes  REF#103
Gleason: Change Gears, Cutter Heads, Cams, Index Plates, Workholding  REF#102
G & E: Change Gears, Arbors  REF#102
Barber Colman: Change Gears, Arbors, Parts for All Models  REF#102
Liebherr: Change Gears, Parts  REF#102
Reishauer: Wheel Mounts  REF#102
JANUARY  2018 53
  

 
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54 gearsolutions.com
 ADVERTISER UNITE-A-MATIC™

INDEX SHOP HARDENED GEAR INSPECTION

WITH DATA COLLECTION
TRUE DIMENSION GEAR INSPECTION™

CONTENTS PAGE NO.

SOFTWARE HIGHLIGHTS
• Real Time Data Collection
ALD Thermal Treatment Inc.................................................................45 • Gauge R&R Studies
• Gauge Database Management
All Metals & Forge Group.....................................................................29

REPORTING HIGHLIGHTS
American Precision Gear Co................................................................25 • Analyze Inspection Data
• Compare Data and Process Behavior
Circle Gear & Machine Co Inc..............................................................11
• Customized Reporting
• Real-Time Reporting

Engineered Tools Corporation..............................................................14

Forest City Gear.............................................................................19, 54

Forest City Gear...................................................................................54

Gleason..................................................................................................2 *NO ANNUAL SOFTWARE FEE

Innovative Rack & Gear........................................................................54

Ipsen USA.................................................................................... IFC, 54 www.unite-a-matic.com

JTEKT Toyoda Americas Corporation................................................IBC

KISSsoft USA LLC...............................................................................25

Koro Sharpening Service.....................................................................54

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Lawler Gear Corporation......................................................................54 DEMAND FOR PRECISION
McInnes Rolled Rings..........................................................................48
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Mitsubishi Heavy Industries America Inc............................................BC Instrumentation • Optic
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New England Gear.................................................................................7 Marine • Defense • Experimental
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Penta Gear Metrology LLC..................................................................37 Hi-Performance Automotive

Russell Holbrook & Henderson Inc......................................................23 Precision Gear Products (up to AGMA Q14):
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United Tool Supply...............................................................................55 Fax (888) FAX-4STD or (508) 580-0071
E-mail info@stdgear.com • Web site: www.stdgear.com
Wickert USA.........................................................................................23

JANUARY  2018 55
 Q&A
WILL TERRY
PRODUCT MANAGER OF SPECIAL PURPOSE MACHINES
JTEKT TOYODA AMERICAS CORPORATION
What’s a typical day like as JTEKT Toyoda Americas
Corporation’s product manager of special purpose
machines — and the leading expert on the award-
winning Gear Skiving Horizontal Machining Centers?
Let’s start by explaining what a special purpose machine is.
Special purpose machines are not necessarily industry-specific, like
automotive grinders, but instead are machines designed with a par-
ticular product in mind. This includes Toyoda’s GS300H, GS700H,
and our newest, most compact model, the GS200H. The division
was conceptualized by combining the mechanical implementations
and control strategies found on the GC20 grinder for camshafts,
the GF50 grinder for crankshafts, and the FH500J Horizontal
Machining Center.
My whole career has been intimately involved in manufacturing.
I came to Toyoda as a service engineer — replacing a customer’s
machine components, improving processes, or writing new programs.
Now as product manager for special purpose machines, I work inten-
sively with customers to match them with their ideal CNC solution
setting them up for maximum profitability.
Tell us about winning the 2017 Automotive News
PACE Award for the High-Speed Axis Synchronization
technology on the Gear Skiving Horizontal Machining
Centers. How did you come to be included in the
nominations?
The PACE Awards recognize technologies that are basically game
changers to the automotive industry for both the consumer and the
manufacturer. In 2017, there were hundreds of applicants, which
were then narrowed down to 32 finalists. Judges from the PACE
panel visited each of the finalists, which provided Toyoda with the
fantastic opportunity of really diving into the unique mechanics of
our submission, showing first-hand our enthusiasm and excitement
for this innovation, and showcasing the technology supporting our
machine that makes profitable high-speed axis synchronization a
reality. This past year, in April 2017, Toyoda was announced as one
of 11 winners, the first machine tool builder in nearly two decades
to be nominated for the award! The overall process was truly amaz-
ing, emotional, and quite the experience! We really are honored to
have our hat in the ring with other big automotive game changers.
Gear skiving is a perfectly coordinated process that takes a high
level of synchronization. It’s almost like an orchestra, if the wood-
winds are a little flat or sharp; they’re going to make the whole band
sound terrible, right? With gear skiving, every component on the
machine has to work in harmony with every other component. Toyoda
released the gear skiving machine to the market at IMTS 2016 but
we really started this journey in 1986 with camshaft grinding. Our
fundamental software and electronic components that make skiving
possible have been under constant development literally for the last
30 years now. With the latest iteration of our control technology, it
made gear skiving really, really attractive.
FOR MORE INFORMATION: www.toyodausa.com
56 gearsolutions.com
Toyoda’s innovation combines
cutting processes, like gear cut-
ting, chamfering, milling, turn-
ing, and deburring, typically
spread amongst several different machines, into one compact and
powerful machine. This saves our customers money not only in the
number of machines needed to produce a part, but in training, servic-
ing the machine, spare parts inventory, man power, and shop floor
real estate. This is the game changer for our customers.
What products and services does Toyoda Americas offer?
Toyoda’s lineup includes horizontal and vertical machining centers,
cylindrical grinders mills, lathes, gear skiving horizontal machining
centers, bridge mills, gantry mills, boring mills, automation solu-
tions, and more.
Aside from receiving the prestigious PACE award, what
are some of the corporation’s proudest moments?
Anybody who’s ever played on a team knows that there are a lot of
people, besides the ones who score the points, who contribute to a
victory. I haven’t been at Toyoda as long as others, so I asked my VP,
‘What are some of our proudest moments?.’ He was really stumped
and that speaks to that team mentality. Anytime Toyoda wins a big
order, the whole corporation lights up; it spreads like wildfire. That
is what we consider a proud moment. The PACE award really show-
cased that team mentality, bringing together applications, marketing,
sales, upper management, facilities, to bring forth the best Toyoda
has to offer in innovation — a great example of what we’re trying to
accomplish with day-to-day sales.
What sets Toyoda apart when it comes to what you can
offer a customer?
Simply put? Service and support. Toyoda machines are backed by an
unparalleled team of service experts each with a unique set of specializa-
tions which is atypical to the industry where everyone is expected to be
an expert on everything. This unique feature allows our customers to
receive a higher level of expertise for their problem. Also, supporting
our customers is a huge team of product experts with access to over
$26 million in inventory, on the shelf, in America, right now, including
parts our customers may need on antiquated equipment.
Where do you see the company in the next 10 years?
Toyoda customers love their machines because they’re so depend-
able and have proven time and time again to have a less expensive
cost of ownership when compared to lower-quality machines. It’s
the reliability behind our product, the technologies we patent, and
the Toyoda team as a whole that continues to make our customers
money and ultimately makes Toyoda machines great investments. In
the next 10 years, I see Toyoda taking more of the market share by
continuing to raise these expectations, pushing industry standards. 
YOUR
GEAR SKIVING
SOLUTION.

Introducing
Toyoda’s Gear Skiving Series.
>
Award Winning

Chuck Less. Risk Less. Pay Less.

JTEKT Toyoda Americas Corporation

316 W. University Drive | Arlington Heights, IL 60004
847.253.0340 | info@toyoda.com
Learn more at www.Toyoda.com/GearSkiving
 1
Input Gear Data
from process sheet
or part print. Input
distance from work
table to bottom of gear.
Our Technologies, Your Tomorrow

CNC Gear
Machine 2
Programming: Input Cutter Data

Easy as
from cutter drawing
or box.

1-2-3 3
Cutting speeds and
feeds automatically
calculated as well
as cutter paths.

Advanced Gear Cutting Capabilities at Your Finger Tips

For more information visit
mitsubishigearcenter.com
or contact Sales at 248-669-6136.
The many-generations-improved Mitsubishi CNC gear cutting machine
simplifies programming like never before. It features Conversational
Programming with built in macros for calculating cutting speeds and feeds
based upon material hardness and gear class with no need to know
complicated G-code programming like traditional CNC machine tools.
Easy to understand graphics and help screens allow new operators
to master programming within a day after installation—and shops that have
never cut a gear before can quickly cut their teeth and expand production.