I On-machine dressing integratethe dre sing unit with the grindinghead to ensure the highest level ofrepeatability Compensation forwheel wear between dresses isautomatic

bull Designed with the flexibility Ito

al 0 grind internal and externalgears with non-dressable Gleasonhigh-precision vitrified or platedCBN wheels

bull On-machine inspection analyzesstock distribution and compensates

for heat treat distortion and parirunout The grinding cycle is optimized

automatically

The bigger the grinding application thebeuer we look From 400to 4000 mm Gleason-Pfauter Profile Grinders can take the limecost and question marks out of your process and put moreprofitability in

I Grinding technology database recommends andoptimizes the perfect production methodology

Call us We 11cut your big grinding challenges down to size

bull K-Chart inspection allows specific inputfor both profile and lead modifications

1000 University Ave POBox 22970Rochester NY 14692-2970 USA

Phone 5amp5473-1()(X) Fax 5854614348Web site wwwgleasoncom E-mail salestsgleasoncom

I Tooth twi t compensation for noise-controlandhigh performance application corrects toothprofile deviations

Gleason delivers the pDwer IMrS 02 - BDDth 6931

JULVAUGUST 2002 I The Journal of Gear Manufacturing _

FEATURES

26

Gear Surface Duralbility Development to iEnhanceTransmissiion Power DensityExperiments to increase pitting resistance in auto transmission gears 20

Performancel A_nalysisof Hypoid Gears bvTooth Flank Form MeasurementDetailed measuring of hypoid gears by scanning machine 26

Minimization of ln-Pmeess Corrosiohl of Aerospace GearsExperiments to reduce corrosion of gears during production 36

IMTS 2002 SPECIAL SECTION

2002 FAQsand Pavilion Info 12

12DEPARTMENTS

2002 Show Indicat8s Minimal Recession DamalgeExpected IMTS attendance 16

Allon - with the Show- 9 - --A technical conference student participationand attractions outside the show 18

__ ---- 52 AddendumA Gear With A Sweet Tooth 12

9

Publishers PageThe E-volution of Gear Technology 7

iRevolutionsEdwin RFellows and a very large gear unit 9

Iindustry NewsWhats happening in the gear industry 32

Technicall CalendarDont miss these important upcoming events 34

Product NewsThe latest products for the gear industry 44

Advertiser IndexNEW Phone numbers and web addresses to make it easier to get information 49

ClassifiedsServices Help Wanted and more 50

In addition we provide you with G8Nand electroplated grinding wheels andworms Ibased on our Ionglexperienceas at developer of grinding technology

Contact us for the latest ingrinding technology

SU America linc5200 Prairie Stone ParkwaySuite 100Hoffman Estates IL 60192Tel 847 649-1450Fax 847 649-01 112E-mail salessuamericacomhttpwwwsuameriicacom

I~ur S400 GT Gear Grinding MachineIS flexible and easy to usa It allowsyou to employ or even combinedifferent grinding technologies liikeprofile grinding continuous generatinggrinding shave grinding (externalhoning) to find the most efficient wayto grind your gear worm or rotor

the S 400 GTaJlows for the adaplationof the latest tool developments -which probably makes it todays mostversatile grinding machine

Fully equipped with todays standardlike linear motor technology and GNG

Hobbing - Profile Grinding - Generating Grinding - Shave Grinding - Chamfering - Deburring - Shaving Culter Grinding_-Bevel Gear Cutting - Tool and Commodity Management Services (eMS)

In addition we provide you with G8Nand electroplated grinding wheels andworms Ibased on our Ionglexperienceas at developer of grinding technology

Contact us for the latest ingrinding technology

SU America linc5200 Prairie Stone ParkwaySuite 100Hoffman Estates IL 60192Tel 847 649-1450Fax 847 649-01 112E-mail salessuamericacomhttpwwwsuameriicacom

I~ur S400 GT Gear Grinding MachineIS flexible and easy to usa It allowsyou to employ or even combinedifferent grinding technologies liikeprofile grinding continuous generatinggrinding shave grinding (externalhoning) to find the most efficient wayto grind your gear worm or rotor

the S 400 GTaJlows for the adaplationof the latest tool developments -which probably makes it todays mostversatile grinding machine

Fully equipped with todays standardlike linear motor technology and GNG

Hobbing - Profile Grinding - Generating Grinding - Shave Grinding - Chamfering - Deburring - Shaving Culter Grinding_-Bevel Gear Cutting - Tool and Commodity Management Services (eMS)

STOCKAVAILABLE17~1i -Route 208 North Fair Lawn New jerseyO7lDTlephone201-796-51145 Fax 201-796middotS664~iE1hEIUti~IIIqatltAIF

Ultra Predse Hobs itUSSELLHOLBROOKampHENIDERSONIINC

Accuracy Class AAA M AMaterials CarbideBridgeHSS

Techno[ogy DryHigh SpeedHard HobbingRange 10 - SOO Diametral Pitchbull Visit our website at httpwwwtru-volulecom

capaI_1ncIud1ng tInII8 elementArrows latest success was utmztng ours1ate-of-1he-art technologies to design thegear t001h geometry and to manufactureall bevel gears in 1he PT1l amp AGB forPratt amp Whitneys PW 6000 engine

2301 Curtiss Streetmiddot Downers Grove IL 60515Tel (630) 969-7640 bull Fax (630) 969-0253

wwwarrowgearcom

I GEAR TECHNOLOGYEDITORIAL

Publisher amp Fdito -iD-Chi~fMichael Goldstein

Managing Editor WiUiam R Stoll

Associate Editor Joseph L Huzelton

Assistant Edilor Robin Wright

Editorial Consultant Paul R Goldstein

Technical EditorsRobert Errichello

Don McVittieRobert E SmithDun Thurman

ARIArt Director Jean Bartz

Advertising Manager Patricia FlamAdv~g Coordinator Angel ica Vi loria

CIRCIJLATI(IN

Circulation CoordinatorsDina Krauss amp Angelica Viloria

INTEIINEl

Web Developer Dan MacKenzie

Gear Indllstry Home Pagel M SalesPatricia Ram

powertransmissioncom TM SalesMichael A Gianfrancesco

lANDAU PUBLISHING STAff

PresidentVice President

ControllerAccountlnomce Coordinator

Michael GoldsteinRichard GoldsteinMichael GrafmanDianne JohnsonGladyce J Cooper

Phone 847437661)4E-mail peoplegearlecll1lofiJgycom

Web wwwgeartechnologycomwwwpowertransmissioncom

VOL 119NO4GFR TEeIlNOL) y lb Journal or ce Iluraclurlng (lSSN 07-13-6858) ls published bimonthlyby Rundall Publishing Inc 1425 Lun Avenue PO Bo1426 Elk Grove village IL 60007 (847) 437middot6bQI Coverprice 5500 US_ Periodical postage puid 01 ArlingaHeigh IL end at addi[ional mailing offic e RandallPubhshing makes e middotcry effort 10 ensure that the processesdolibed n GEAR TECHNOLOGY conform 10ad enga-nerm~ practice Neither the umbers 1lIJT the pubhsber can beheld respcnn ble for injuries susralned while following theprocedures described Postmaster Send uddress cbunges 10GEAR TECHNOLOGY The Journal of GearManufncturf ng 1425 Lum Avenue PO Bu L426 ElkOrolt Village IL 60001 OConlnts ropyriglllL-d by RANmiddotDALL PlBLISHlNG [NC 2002 No pen of lh publica-[ion ma) be reprod ueed or uansmmed in an) form or by an)mCQn~ electronic Or mechanleuj indudingthou-cop) ingrecording or by any informauon storage an rerneval sys-tem wuhour permission in wriing from [he publisherContents or ud-iltare oubJecl to Publishers approval

4 JUL YAUGUST 2002 bull GEAR TECHNOLOGY wwwg8srlechnologycom bull wwwpowarlransmjs5ioflcom

MACHINE Up To

MORE PARTSPER HOUR

Dura-Bar Plus is a new engineered ironthat machines better than carbon and alloysteels and better than competitive grades of

continuous cast ironNew amp Improved Dura-Bar Plus gives you

A LOWER CO TPERPART bullbullbull

PLiUS - MORE PART PER HOURIDecrease cycle timeIncrease productivity

PLUS - LONGER INSERT LIFEReduce your downtime fortooling change

PLUS - A DEFEO-FREE MATERIALQuality guaranteed

Dura-Bar Plus is available in gray and ductileiron grades and in a wide variety of sizesand shapes For more information sec

web site at wwwdura-barcom

Or callI-SOD-BAR MILL(1-800-227 -6455)

INCREASE 0 R MJClDNlNGPRODUcrWITI A~D S4[ MONEl wrrn

New Dura-Bar Plus THE LATESTI ENGlNiELRJD l1ETA~TECHNOLOGl

Continuous Cast IronBar Stock21100 West Lake Shore Drive Wood5tockl~L 6009s69 I II-SOO-BAR-MILL bull 815-338-7800 bull FAX 815middot338middot1549E-mail salesdura-barcom Internet wwwdura-barcom

LMT-FEITE end LIEBHERRfor gear cutting otutions

LMT-FETTEslegendary craftsmanship and precision haveearned us a world-wide reputation for producing hobs thallarleunsurpassed in the gear industry Now we roudl announcea newpafitnership lin the North Amedcan market withLIIEiBHIERiRthe industry leader of LORENZreg$haping shavingand gauging tools By combining the strengths of these globalleaders weare now North Americassingle-source solutionlprovider in the gear industry

Combining premium materials stmiddotalte-of-the-art coatingsand the most advanced heat-Irealting processes we prlovidegear cuttingl tools that out-per1orm all others Our continuallinvestment in research and development ensures each LMTFETTE and LORENZreg product is designed alnd built toexceedlyour performance expectations

All LMT-FETTE and LIEBHiERRgear cutling toolsare manufactured to AGMA and DIN standards

Solid HSS HobsSolid Carbide HobsMulti-Gash HobsHeavy Duty Roughing HobsIndexable Carbide Insert Roughing IHobsMilliing Cutters with Carbide InsertsSkiving HobsHobs for Worms Sprockets RotorsTiming Belt Pulleys amp _ ShapeI CuttersForm Milling CuttersShaving TbolsRack TY1gteCuttersRolling DiesRolling RacksBroach RingsMaster GearsAling and Plug GaugesCutter AdaptersClamping ArborsClamping Fixtures

Call our new Gear Solution Centerin Saline Michigan at 734-429-2095

10 tindouf how we can be yoursingle~source solution provider

18013 Cleveland

rLMT bull-FETTE

Cleveland Ohio 44135

-------- -

PUBUSHERS PAGE _

The E-volution ofGear TechnologyTechnology creates excitement lust consider the natural

buzz around IMTS where manufacturers will go to explore

ways they can increase productivity improve quality decrease

costs or provide better service

But technology is not just for manufacturers At GearTechnology were creating a buzz of OUT own That buzz is over

EmiddotG the next phase in OUl technological evolutlon E-GTstands for Electronic Gear Technology IIs one of the biggestchanges weve made in ]8 years and its going to make access

10 Gear Technologys information easier than ever beforeBeginning with the JanuaryFebruary 2003 issue the entire COI1-

tents of the magazine will be available electronically Thatincludes all the articles all the advertisements all the figuresand formulas exactly as they appear in the print version

Of course were not changing the printed magazine The reg-ular version of Gear Technology will continue to be available toall our qualified US readers=-for free-just as it always has

Also people outside the United States will still be able to pur-chase subscriptions 0 the printed version

Pan of what makes E-GTexciting is that were doing some-thing thai very few other magazines are able or willing to do

While weve always brought you information on leading edge

technology related to gear manufacturing E-GT keeps us on theleading edge ourselves Im proud of thai capability But whats

really exciting about E-GT is how it will enable us to better

serve our industryE-GT means that qualified subscribers wiU have access (Q an

exact copy of our magazine in PDF format) via The GearIrtdrlstry Home PageThI Youll be able 10 retrieve an electronic

version of the current i sue whenever you want Youll be ableto store it on your hard drive to create an archive of issues foreasy reference And youll be able to search through a particularissue for keywords or company names Youll be able to receiveE-GT when youre traveling Youll be able to carry it on your

laptop or bum it onto a CDSince we began publishing Gear Technolog) in 1984 our

mission has been to serve the gear industry with the best possi-ble technical and educational information related to the designprocessing manufacturing and inspection of gears Today ourmission is the same E-GT makes it easier for LIS to carry it out

For example wilth each passing year the gear industry has

become more global Until now weve had to charge subscribers

outside the United States to offset the substantial costs of mail-

ing the magazine E-GTeliminales those costs It will be avail-

able for free to qualified subscribers anywhere in the world

Another benefit for subscribers outside the United Stales isthat they II no longer have to wait two or more weeks extra 10

receive their issues by mail Theyll have access to the contentas soon as the issue is published and the electronic version isuploaded to our website

To ensure that our magazine is reaching the right audience

our electronic subscribers will fill out 1 qualification card onceper year just as they do with our printed version Part of thatqualification card will include the subscribers e-mail address

When each issue becomes available online well e-mail the

subscribers a notice to Ie them know they can download theissue at their convenience

pound-GTis a continuation of the process we began in 1996 with

the launching of The Gear Industry Home Pagetrade whichremains the Internets premier marketplace for the machinerycutting tools and services

related to gear manufactur-ing In 1997 we launched

powertraIJSlllissiollcomtradeto serve as a portal for man-ufacturers and buyers ofgears gear dri ves and otherpower transmission compo-nents Today those twowebsites deliver more than

200000 page views and50000 user sessions permonth Theyve grown evolved and taken all a life of their

own becoming an everyday pan of the fabric of the industry I

expect E-GT to do the same

Michael GoldsteinPublisher amp Editor-ill-Chief

PS Those of you who Ire interested in becoming E-G1 subscriberscln now log on to Th GoIffIUIfIy H IIge Ind fill out tilesimple qualificetion form Visit wwwgeltIChnDlogycom andlook for the E-G1button Were interested in your commenllibouthow E-G1 and our other prodIcts can ate you more tfftctive Indsuccessful Whl ide do yoI have that WI hlvent thought of yetLet us hear from you pBOplt41geltIChnologycDfll

wWIWpowerfransmluioncommiddot WWWgearlechnologycom bull GEAR TECHNOLOGYmiddot JULVAUGUST 2002 7

-------- -

PUBUSHERS PAGE _

The E-volution ofGear TechnologyTechnology creates excitement lust consider the natural

buzz around IMTS where manufacturers will go to explore

ways they can increase productivity improve quality decrease

costs or provide better service

But technology is not just for manufacturers At GearTechnology were creating a buzz of OUT own That buzz is over

EmiddotG the next phase in OUl technological evolutlon E-GTstands for Electronic Gear Technology IIs one of the biggestchanges weve made in ]8 years and its going to make access

10 Gear Technologys information easier than ever beforeBeginning with the JanuaryFebruary 2003 issue the entire COI1-

tents of the magazine will be available electronically Thatincludes all the articles all the advertisements all the figuresand formulas exactly as they appear in the print version

Of course were not changing the printed magazine The reg-ular version of Gear Technology will continue to be available toall our qualified US readers=-for free-just as it always has

Also people outside the United States will still be able to pur-chase subscriptions 0 the printed version

Pan of what makes E-GTexciting is that were doing some-thing thai very few other magazines are able or willing to do

While weve always brought you information on leading edge

technology related to gear manufacturing E-GT keeps us on theleading edge ourselves Im proud of thai capability But whats

really exciting about E-GT is how it will enable us to better

serve our industryE-GT means that qualified subscribers wiU have access (Q an

exact copy of our magazine in PDF format) via The GearIrtdrlstry Home PageThI Youll be able 10 retrieve an electronic

version of the current i sue whenever you want Youll be ableto store it on your hard drive to create an archive of issues foreasy reference And youll be able to search through a particularissue for keywords or company names Youll be able to receiveE-GT when youre traveling Youll be able to carry it on your

laptop or bum it onto a CDSince we began publishing Gear Technolog) in 1984 our

mission has been to serve the gear industry with the best possi-ble technical and educational information related to the designprocessing manufacturing and inspection of gears Today ourmission is the same E-GT makes it easier for LIS to carry it out

For example wilth each passing year the gear industry has

become more global Until now weve had to charge subscribers

outside the United States to offset the substantial costs of mail-

ing the magazine E-GTeliminales those costs It will be avail-

able for free to qualified subscribers anywhere in the world

Another benefit for subscribers outside the United Stales isthat they II no longer have to wait two or more weeks extra 10

receive their issues by mail Theyll have access to the contentas soon as the issue is published and the electronic version isuploaded to our website

To ensure that our magazine is reaching the right audience

our electronic subscribers will fill out 1 qualification card onceper year just as they do with our printed version Part of thatqualification card will include the subscribers e-mail address

When each issue becomes available online well e-mail the

subscribers a notice to Ie them know they can download theissue at their convenience

pound-GTis a continuation of the process we began in 1996 with

the launching of The Gear Industry Home Pagetrade whichremains the Internets premier marketplace for the machinerycutting tools and services

related to gear manufactur-ing In 1997 we launched

powertraIJSlllissiollcomtradeto serve as a portal for man-ufacturers and buyers ofgears gear dri ves and otherpower transmission compo-nents Today those twowebsites deliver more than

200000 page views and50000 user sessions permonth Theyve grown evolved and taken all a life of their

own becoming an everyday pan of the fabric of the industry I

expect E-GT to do the same

Michael GoldsteinPublisher amp Editor-ill-Chief

PS Those of you who Ire interested in becoming E-G1 subscriberscln now log on to Th GoIffIUIfIy H IIge Ind fill out tilesimple qualificetion form Visit wwwgeltIChnDlogycom andlook for the E-G1button Were interested in your commenllibouthow E-G1 and our other prodIcts can ate you more tfftctive Indsuccessful Whl ide do yoI have that WI hlvent thought of yetLet us hear from you pBOplt41geltIChnologycDfll

wWIWpowerfransmluioncommiddot WWWgearlechnologycom bull GEAR TECHNOLOGYmiddot JULVAUGUST 2002 7

Productivity ls synonymlous withKllingelnberg-Oerlikon

Our vision is the longlerm technological palnnershipwiithl our cusiomersOur Boall isla help ourcustomersto deliver top qualily axleswith maximum cost efficiency This is why Klingelnberg-Oerlikondeveloped the dry cutting process with stcte-ol-the-crttechnology equipment - and no one has more experience

See US at IMTS2002 Booth S7040 -

REVOLUnONS

Edwin IRIFeliowsShapiing the Oear -IndustryOn July 13 1896 a former window

dresser received a $5000 budget to start

a company for making his far-reachinginvention the gear shaper machine

The former window dresser wasEdwin R Fellows from Torrington CTThe money was from subscribers (readventure capitali ts) And his inventionwas an idea he worked on while a drafts-

man at Jones amp Lam on Machine Co inSpringfield VT

In 1916 the Fellows Gear Shaper Coreached $1 million in machinery sales

for the first lime The business thatbecame Fellows Corp was on its way

By then Fellows was a director of his

companyIn 1896 though he was its 31-year-

old manager with a workforce of sevenpeople His first gear shape] machine

was completed in 1897 though an exper-imental version had been built in 1896 ata machine shop in Fitchburg MA

Fellows machine introduced a newtype of gear-culling tool His shaper cut-

Edwin R Ifellows Thill tonner window dressermade good as the inventor of tbe gear sbapermachine

Whitney knows about Fellows and his Also Fellows gear shaper could

company from work-related research and make shoulder gears two different-wwwpow6rransmlssloncommiddot wwwg6artachnologycommiddot GEAR TECHNOLOGY JULYAUGUST 2002 9

ter was a hardened ground gear with

sharpened teethAt that time no one else was making

gear (shaper) cutters says Don

Whitney a former manager of Fellows

Corp s cutter-engineering department

By 1905 Fellows company wasalready having an impact on the automo-

bile industry That impact is reflected inPrecision Valley an account of the

machine-tool industry that developed inthe valley where Springfield is located

The book lists automobile manufac-turers that were Fellows customers in1905 Those manufacturers includedBuick Motor Co Packard Motor Car

Co Olds Motor Works Dodge BrothersCadillac Motor Car Co and Pierce-Arrow Motor Car Co

Before his companys start though

Fellows got his start in Springfield withthe help of a mend James Hartness

Hartness is remembered as a promi-nent Vermont industrialist and public fig-ure He is credited with 12() patents

ranging from the flat turret lathe to asafety razor Irt 1900 he became presi-dent of Jones amp Lamson In 1921 hebecame Vermonts governor

In 1889 though Hartness was anemployee at Jones amp Lamson and wasurging his Connecticut friend to join himFellows did so and became a Jones ampLamson employee in 1889

The future industrialists knew eachother through Fellows mother

Years eartier Fellows father bad died

while Fellows was in high schoolAfterward Fellows mother took in

boardersYoung Hartness was one of the

boarders Whitney says He and Edwin

were good friends

personal curiosity For a time Whitneytaught a cutter design course at FellowsCorp so he researched the companys

history to create a preface for the booklet

used in the course

As for his personalcuriosity the 45-

year employee of Fellows Corp say Im naturally interested in it becau ethat was my life

Fellows invention received publicrecognition just a few years after hiscompanys start

In 1899 Fellows received the JohnScott Award from the city of Philadel-phia for his gear shaper machine and cut-ter The award is given to men andwomen whose inventions contribute in

outstanding ways to peoples comfortwelfare and happiness Other recipientsof the award include Marie CurieThomas Edison Jonas Salk and Orville

and Wilbur WrightFellows machine made gears by sim-

ulating the meshing of two gears rotatingaround two parallel axes A gear blank

would be mounted on a vertical arbor Acomplete gear the cutter would then

move up and down as it and the blankslowly revolved synchronously

As Whitney explains one cuttercould produce spur and helical gear ofany size with any number of teeth-whether they were external or internalgears LTC Holt though notes arestriction in his book A Shorr History ofMachine Tools Fellows cutter could

make different-sized gears so long astheir pitches were the same and the

gears teeth had the helix angle the cutterwas made to create

Whitney says that ability representeda significant advance in gear manufac-

turing

sized gears on the same shaft with littleclearance between them That abilitypermitted more compact design of auto-mobile transmissions

In Holts opinion though Fellowscutter-grinding machine was more sig-nificant than his gear shaper machine Heexplains that Fellows precision grindi ngmachine foreshadowed the grinding ofhardened gears as a common step in pro-duction

Fellows worked for his company forthe rest of his life He was president and

REVOLUTIONS

director when he died May 21 1945Fellows Corp continued to serve gear

manufacturers for another 57 years Itstopped operations Feb 13 its parentcompany filing for bankruptcy

On May 23 BF Acquisition won itsbid for Fellows Corp BF Acquisition isan affiliate of Park Corp an Ohio-basedcompany

As reported in the Rutland Herald ofRutland VT BF Acquisition bid $372million for the company

BF Acquisitions purchase was

bull Threads Helicaland Involute

bull Straighl or TSperedSplines on Shalb110ProduclionRolling

Palenleo MotorizedBolling MillingGrinding amp ClusterRepair or Desiln IIIBuild

3BROACHTOOLS

bull Helical Spirax bullIarg8 InvolutesFlat Concave IIISpecial Forms

bull Pltenled CNIlManufacturedllorConsistency

4 IBRIIACIlINGMACHINES

middotCNelHelicalTable UpPull DownSurface lidHorizontal

bull Complet8 TurnkeySetups

Colonial ToollGroup Inc has been a leader in the machine toolindustlry for over 60 years Our reiPutation can only be maintaiinedIbythe manu1actu1ring of alii our products in-house including acomplete heat Ileat facility Iet ustackle your tooling needs orprocess Iproblems from our previous experience balanced withtodays ingenuity

With exchange rates your US dollars bu-V more in Canada

COt~ONIALTOOL GIROUP INC16911Walker Road Windsor Ontario Canada N8W 31gt1

519-253-2461 bull fAX 519-253-59n bull wwweolonialtoolcomln the USA 3113-965-8680

advantage because multiple stages of10 JULYfAUGUST 2002 bull GEAR TECHNOLOGY wwwgearrechnDJogyCom WWwpoW9rfrBnsmissJoncom

expected to receive final approval May28 from US Bankruptcy Court inDelaware Closing on the sale wasexpected to occur May 31

A Two~StoryGear UnitBHS-Cincinnati Getriebetechnik GmbH

of Sonthofen Germany recently deliv-ered what it says is the worlds large t

integral gear unit at more than 5 meterswide more than 45 meters tall andweighing more than 42 tons The gearunit was sold to MA TurbomaschinenAG GHH Borsig of Berlin a Germancompressor manufacturer

MAN Turbomaschinen eu tomer aChinese chemical plant plans to use thisgear unit for manufacturing purefiedterephthalic acid (PTA) a material usedin polyester fiber production

Whats unique about these large inte-gral gear units is that the compressor isnot mounted in line with the gear drivebut is directly mounted to the gear cas-ing says BHS engineering sales manag-er Stefan Burkart With this arrange-mentthe efficiency rate can be signifi-cantly improved and the space require-ment significantly reduced versus tradi-tional stand-alone units

Other companies make this kind ofdevice but this one is larger than mostHowever similar sized integral gearunits are sold by Flender Corp ofBochoh Germany bulland SMS Dernag AGof Dusseldorf Germany

The primary advantage of the integralgear unit is the compact instajlauon itprovides through the elimination of thecoupling along with the capability ofmounting the compressor housingdirectly to the gearbox says PatrickPotter sales engineer at BHS-CincinnaliEven for single-pinion units this i a ig-nificant advantage because the compres-sor housing can be overhung from theskid which allows much more flexibili-ty in piping arrangements for the com-pressors process ga

For multiple-pinion units the abilityto mount the compressor casings direct-ly ~Q the gearbox is a technical and co t

REVOLUnONS

Edwin IRIFeliowsShapiing the Oear -IndustryOn July 13 1896 a former window

dresser received a $5000 budget to start

a company for making his far-reachinginvention the gear shaper machine

The former window dresser wasEdwin R Fellows from Torrington CTThe money was from subscribers (readventure capitali ts) And his inventionwas an idea he worked on while a drafts-

man at Jones amp Lam on Machine Co inSpringfield VT

In 1916 the Fellows Gear Shaper Coreached $1 million in machinery sales

for the first lime The business thatbecame Fellows Corp was on its way

By then Fellows was a director of his

companyIn 1896 though he was its 31-year-

old manager with a workforce of sevenpeople His first gear shape] machine

was completed in 1897 though an exper-imental version had been built in 1896 ata machine shop in Fitchburg MA

Fellows machine introduced a newtype of gear-culling tool His shaper cut-

Edwin R Ifellows Thill tonner window dressermade good as the inventor of tbe gear sbapermachine

Whitney knows about Fellows and his Also Fellows gear shaper could

company from work-related research and make shoulder gears two different-wwwpow6rransmlssloncommiddot wwwg6artachnologycommiddot GEAR TECHNOLOGY JULYAUGUST 2002 9

ter was a hardened ground gear with

sharpened teethAt that time no one else was making

gear (shaper) cutters says Don

Whitney a former manager of Fellows

Corp s cutter-engineering department

By 1905 Fellows company wasalready having an impact on the automo-

bile industry That impact is reflected inPrecision Valley an account of the

machine-tool industry that developed inthe valley where Springfield is located

The book lists automobile manufac-turers that were Fellows customers in1905 Those manufacturers includedBuick Motor Co Packard Motor Car

Co Olds Motor Works Dodge BrothersCadillac Motor Car Co and Pierce-Arrow Motor Car Co

Before his companys start though

Fellows got his start in Springfield withthe help of a mend James Hartness

Hartness is remembered as a promi-nent Vermont industrialist and public fig-ure He is credited with 12() patents

ranging from the flat turret lathe to asafety razor Irt 1900 he became presi-dent of Jones amp Lamson In 1921 hebecame Vermonts governor

In 1889 though Hartness was anemployee at Jones amp Lamson and wasurging his Connecticut friend to join himFellows did so and became a Jones ampLamson employee in 1889

The future industrialists knew eachother through Fellows mother

Years eartier Fellows father bad died

while Fellows was in high schoolAfterward Fellows mother took in

boardersYoung Hartness was one of the

boarders Whitney says He and Edwin

were good friends

personal curiosity For a time Whitneytaught a cutter design course at FellowsCorp so he researched the companys

history to create a preface for the booklet

used in the course

As for his personalcuriosity the 45-

year employee of Fellows Corp say Im naturally interested in it becau ethat was my life

Fellows invention received publicrecognition just a few years after hiscompanys start

In 1899 Fellows received the JohnScott Award from the city of Philadel-phia for his gear shaper machine and cut-ter The award is given to men andwomen whose inventions contribute in

outstanding ways to peoples comfortwelfare and happiness Other recipientsof the award include Marie CurieThomas Edison Jonas Salk and Orville

and Wilbur WrightFellows machine made gears by sim-

ulating the meshing of two gears rotatingaround two parallel axes A gear blank

would be mounted on a vertical arbor Acomplete gear the cutter would then

move up and down as it and the blankslowly revolved synchronously

As Whitney explains one cuttercould produce spur and helical gear ofany size with any number of teeth-whether they were external or internalgears LTC Holt though notes arestriction in his book A Shorr History ofMachine Tools Fellows cutter could

make different-sized gears so long astheir pitches were the same and the

gears teeth had the helix angle the cutterwas made to create

Whitney says that ability representeda significant advance in gear manufac-

turing

sized gears on the same shaft with littleclearance between them That abilitypermitted more compact design of auto-mobile transmissions

In Holts opinion though Fellowscutter-grinding machine was more sig-nificant than his gear shaper machine Heexplains that Fellows precision grindi ngmachine foreshadowed the grinding ofhardened gears as a common step in pro-duction

Fellows worked for his company forthe rest of his life He was president and

REVOLUTIONS

director when he died May 21 1945Fellows Corp continued to serve gear

manufacturers for another 57 years Itstopped operations Feb 13 its parentcompany filing for bankruptcy

On May 23 BF Acquisition won itsbid for Fellows Corp BF Acquisition isan affiliate of Park Corp an Ohio-basedcompany

As reported in the Rutland Herald ofRutland VT BF Acquisition bid $372million for the company

BF Acquisitions purchase was

bull Threads Helicaland Involute

bull Straighl or TSperedSplines on Shalb110ProduclionRolling

Palenleo MotorizedBolling MillingGrinding amp ClusterRepair or Desiln IIIBuild

3BROACHTOOLS

bull Helical Spirax bullIarg8 InvolutesFlat Concave IIISpecial Forms

bull Pltenled CNIlManufacturedllorConsistency

4 IBRIIACIlINGMACHINES

middotCNelHelicalTable UpPull DownSurface lidHorizontal

bull Complet8 TurnkeySetups

Colonial ToollGroup Inc has been a leader in the machine toolindustlry for over 60 years Our reiPutation can only be maintaiinedIbythe manu1actu1ring of alii our products in-house including acomplete heat Ileat facility Iet ustackle your tooling needs orprocess Iproblems from our previous experience balanced withtodays ingenuity

With exchange rates your US dollars bu-V more in Canada

COt~ONIALTOOL GIROUP INC16911Walker Road Windsor Ontario Canada N8W 31gt1

519-253-2461 bull fAX 519-253-59n bull wwweolonialtoolcomln the USA 3113-965-8680

advantage because multiple stages of10 JULYfAUGUST 2002 bull GEAR TECHNOLOGY wwwgearrechnDJogyCom WWwpoW9rfrBnsmissJoncom

expected to receive final approval May28 from US Bankruptcy Court inDelaware Closing on the sale wasexpected to occur May 31

A Two~StoryGear UnitBHS-Cincinnati Getriebetechnik GmbH

of Sonthofen Germany recently deliv-ered what it says is the worlds large t

integral gear unit at more than 5 meterswide more than 45 meters tall andweighing more than 42 tons The gearunit was sold to MA TurbomaschinenAG GHH Borsig of Berlin a Germancompressor manufacturer

MAN Turbomaschinen eu tomer aChinese chemical plant plans to use thisgear unit for manufacturing purefiedterephthalic acid (PTA) a material usedin polyester fiber production

Whats unique about these large inte-gral gear units is that the compressor isnot mounted in line with the gear drivebut is directly mounted to the gear cas-ing says BHS engineering sales manag-er Stefan Burkart With this arrange-mentthe efficiency rate can be signifi-cantly improved and the space require-ment significantly reduced versus tradi-tional stand-alone units

Other companies make this kind ofdevice but this one is larger than mostHowever similar sized integral gearunits are sold by Flender Corp ofBochoh Germany bulland SMS Dernag AGof Dusseldorf Germany

The primary advantage of the integralgear unit is the compact instajlauon itprovides through the elimination of thecoupling along with the capability ofmounting the compressor housingdirectly to the gearbox says PatrickPotter sales engineer at BHS-CincinnaliEven for single-pinion units this i a ig-nificant advantage because the compres-sor housing can be overhung from theskid which allows much more flexibili-ty in piping arrangements for the com-pressors process ga

For multiple-pinion units the abilityto mount the compressor casings direct-ly ~Q the gearbox is a technical and co t

sized gears on the same shaft with littleclearance between them That abilitypermitted more compact design of auto-mobile transmissions

In Holts opinion though Fellowscutter-grinding machine was more sig-nificant than his gear shaper machine Heexplains that Fellows precision grindi ngmachine foreshadowed the grinding ofhardened gears as a common step in pro-duction

Fellows worked for his company forthe rest of his life He was president and

REVOLUTIONS

director when he died May 21 1945Fellows Corp continued to serve gear

manufacturers for another 57 years Itstopped operations Feb 13 its parentcompany filing for bankruptcy

On May 23 BF Acquisition won itsbid for Fellows Corp BF Acquisition isan affiliate of Park Corp an Ohio-basedcompany

As reported in the Rutland Herald ofRutland VT BF Acquisition bid $372million for the company

BF Acquisitions purchase was

bull Threads Helicaland Involute

bull Straighl or TSperedSplines on Shalb110ProduclionRolling

Palenleo MotorizedBolling MillingGrinding amp ClusterRepair or Desiln IIIBuild

3BROACHTOOLS

bull Helical Spirax bullIarg8 InvolutesFlat Concave IIISpecial Forms

bull Pltenled CNIlManufacturedllorConsistency

4 IBRIIACIlINGMACHINES

middotCNelHelicalTable UpPull DownSurface lidHorizontal

bull Complet8 TurnkeySetups

Colonial ToollGroup Inc has been a leader in the machine toolindustlry for over 60 years Our reiPutation can only be maintaiinedIbythe manu1actu1ring of alii our products in-house including acomplete heat Ileat facility Iet ustackle your tooling needs orprocess Iproblems from our previous experience balanced withtodays ingenuity

With exchange rates your US dollars bu-V more in Canada

COt~ONIALTOOL GIROUP INC16911Walker Road Windsor Ontario Canada N8W 31gt1

519-253-2461 bull fAX 519-253-59n bull wwweolonialtoolcomln the USA 3113-965-8680

advantage because multiple stages of10 JULYfAUGUST 2002 bull GEAR TECHNOLOGY wwwgearrechnDJogyCom WWwpoW9rfrBnsmissJoncom

expected to receive final approval May28 from US Bankruptcy Court inDelaware Closing on the sale wasexpected to occur May 31

A Two~StoryGear UnitBHS-Cincinnati Getriebetechnik GmbH

of Sonthofen Germany recently deliv-ered what it says is the worlds large t

integral gear unit at more than 5 meterswide more than 45 meters tall andweighing more than 42 tons The gearunit was sold to MA TurbomaschinenAG GHH Borsig of Berlin a Germancompressor manufacturer

MAN Turbomaschinen eu tomer aChinese chemical plant plans to use thisgear unit for manufacturing purefiedterephthalic acid (PTA) a material usedin polyester fiber production

Whats unique about these large inte-gral gear units is that the compressor isnot mounted in line with the gear drivebut is directly mounted to the gear cas-ing says BHS engineering sales manag-er Stefan Burkart With this arrange-mentthe efficiency rate can be signifi-cantly improved and the space require-ment significantly reduced versus tradi-tional stand-alone units

Other companies make this kind ofdevice but this one is larger than mostHowever similar sized integral gearunits are sold by Flender Corp ofBochoh Germany bulland SMS Dernag AGof Dusseldorf Germany

The primary advantage of the integralgear unit is the compact instajlauon itprovides through the elimination of thecoupling along with the capability ofmounting the compressor housingdirectly to the gearbox says PatrickPotter sales engineer at BHS-CincinnaliEven for single-pinion units this i a ig-nificant advantage because the compres-sor housing can be overhung from theskid which allows much more flexibili-ty in piping arrangements for the com-pressors process ga

For multiple-pinion units the abilityto mount the compressor casings direct-ly ~Q the gearbox is a technical and co t

REVOLUTilONS

Standing talll at 45metllrs and weighillg in at 42tons this integral gear unit hom BHSmiddotCincinnatilieuiebetech~k GmblI ofSaniliofeu Gellllan-y is(he rllsult of work by 8 tea m of enginears andwas cold to Cbinese chemical plant

compression canal be handled by onegearbox in lead of requiringevera]

separate stand-alone units Potter saysThe space-efficiency of the integral

gear unit is accompanied by operating

efficiency=-thrust collars eliminate theneed for higb speed thrust bearings andpower losses are typically lower thanstand-alone unit Also iacethe journal

bearings for the compressor wheel arediminated (the impellers are mounted on

the pi nions and the compressor uses gearunit bearings) a further redaction in sys-tem power los is realized

The freedom in electing differentpinion peeds allow an optimization of the aerodynamic efficiencyin each tage of compression Potter ays Thisexplains why the overall power loss ofan inregralgeared compres or i typical-ly much lower than rand-alone unit

With the ability to drive up to toflange-mounted impellers the units are

equipped with thrust collars to eliminatethe high speedthrust bearings The col-lars transfer the th rust to the bull gear

where the axial load is taken bya [owpeed thrust bearing The compressors

impellers are eared all extended pinionshaft and the pirafhousing are flangemounted onto the gear housing

Featuring ingle-helical gearing withpinion of thrust collar de ign the gear-box design holds upper and lower hou -109 components for two- to four-stageapplications For five- to eight- tage

1 -------

designs customers can use upper middleand lower hou mg component

To have nine- and IO-stage compres-or applications the customer has to

install a fifth pinion below the bun gearThis pillion also call drive the bull gearand gearbox for turbine applications

Regardless of the end use Europeansare buying tile integral gear unit elll

masse Since February 50 units have

been sold by BHSmiddotCincinnati which ismanufacturing them at a rate of about

100 units a year A full 90 percent of

these machines are sold in Europe forU)OOOO to 1 million euros or about$92000 to $9[8000 apiece The rest of

the sales are split between companies inAmerica and JapanO

Ten Us Whit You Think VIIH wwwlHroIogycomtobull RIle dIiI col bull __ 11hnIIionbull COIIIct lite COIIIPIIiet

H9 h PerformanceLIIi(le YOIUVlel Neiver

Seenl Befolre

The RZ 400 reduces manufacturing costs tIlroughbull Increased flexibility for a variety 01 tooth geometriesbull Substantially faster cycle timesbull Rapid changeovers lor small lot size productionbull Automatic loading as a standard option

Make a pit stop in the Reishauer booth to have one ofour Pertormance Team take for you lor a spin aroundthe future of hard gears

Come See the INew Reishauer RZ4DOIn Aclion bull

flEISHAUEFIReishauer Corporation Elgin Il60123ph 847-888-3828 fax 847-888Q343VNffl reishauercom

IIIIIIIIIIIIpollll8rrsnsmissioncommiddot IIIIIIII(J811rI9Chnoio1ycom bull GEAR TECHNOLOGY JULYIAUGUST 2002 11

You know Reishauerlor superior ContinuousGenerating Gear Grindingmachines This year at

IMTS along with a complete line of DiamondlIDrBssing TOlIls well introduce Ihe completelynew RZ 400 Incorporating all of the successfultechnology of our past series and much morethe new RZ 400 will revolutionize the wayspur and helical gears are ground

_ bullbull -- -IIIMTS20021 ----------

Robin Wright

20O-2-FAQ-- ~-Id- Pasilion InfoI _ IS an _ __ _ _IMTS PAVIUO IS

Abrasive MachiningJSawingJIFlinislling-North Building HaIlIBThis pavilion will feature cylindrical grinders internal grindersangular wheelside grinders creep feed grinders thrufeedgrinders centerless grinders surface grinders abrasive beltgrinders jig grinders CNC tool and cutter grinders universalgrinders earngrinders bench crankshaft and abrasive cutoffmachines band saws circular saws lapping machines balanc-ing machines honing machines and polishing machines

IControlsand CAD-CAMI-EastIBuilding Halll DThis pavilion focuses on CIMICADCAM systems CNC con-trols automation management systems communications sys-

terns and LANs software development systems and servicescomputers and software instruments-controls and systems inte-gration services

IEDMI-East Buildingl HalilDOne of the Jargest gatherings of EDM manufacturers everassembled the pavilion features C C wire EDM EDM filtra-tion system and supplies ram-type EDM metal disintegratorsand die sinking machines

12 JULYAUGUST 2002 GEAR TECHNOLOGY wwwg6llrtechnologycom wwwpowerlransmlssloncom

_____ IIMTS2002 _

Gear Generation-North Buiildingl Hall BGear bobbers gear shapers gear cutter gear shavers broach-

ing equipment gear grinding equipment and gear measuring

equipment are howcased in this pavilion

Machine ComponentsCleanilngjEnvironmenCaI-East BuildingHall DAir purification equipmeot and services satety guards mats andequipment filtralion equipment water and oil purification air fil-tration oil separation ump cleaners noise control equipment

dust removers electrical equipment way coverstracks storagesystems parts cleaners parts washers materials handlingstorage

ystem ball crews bearings spindle conveyors coatings

ervo motor pumps degreasers robotics plant maintenance

equipment assemblytest equipment motion control equipment

and environmental management software are featured

MetalllCuttin~South Building Hall A andilNorth BuildingIHall CThe Metal CUlling Pavilion include machining centers turn-

ing centers assembly automation milling machines and cen-

rers boring machines drilling machines tran fer machines

screw machine broaching machine burnishing machines

gun drilling machines plaaerrnills boring mills multiple

spindle drills and automatics drillmillbore heads and slides

thread rolling jig boringmilling machines and knurling

machines vertical turret lathes bar feeds automation systemsa embly machine end finishers machining cells chuckers

and CNC lathes

Metai forming amp IFabricainglaser-North Building Na1II BAll types of presses and the latest in la er production Slid tech-

nology are displayed here

Quality AssurancHeast Building Hall 0Precision laser and coordinate measuring machines automated

precision and in-process gaging machines too] condition mon-

itoring equipment measurement software quality control test-

ing and measuring equipment comparators metrology and

vi ion ystems willi be on display

Tooling amp Workhoiding Sw-stems-Easamp Building IHallllEThis pavilion ha special toohng indudillg boring bars

coolarus oils ceramics and composite cutting tools gun

drilling systems jigs reaming tools and vises

BlIsiness Services-North Building Concourse LobbyHere you will find industry-related publications government

organization and other lion-manufacturing organizations

Fassler111~gh quaUty and comPcetitive ~g From the people who invented ine Fassler eSA Grinding WheelDressing processWe would like tOI present our new module rongeof diamondldressers for flank and tip Idressing

Yourban Bfitsbull Increased tooillifebull Attractive factory-direct priCingbull Original Swiss-precision qualitybull Higher wear resistancebull Better cutting abilitybull Short deliverybull For Fassler DSA Reishauer SPA and RP2s~stems

Contact us with your requirements atFassler Corporationm WILayton AYeSte 308 Milwaukee WII 53201PlhDne14141769-0072- Fax 141411769b8610E-mail IUsafaessler-agcbl

NEW MODEL0-3 Capacity Shop Hardened

Lowest cost in the industryI

Call to use gage for yournext maehine sun otl90 days at nocharge

United Tool Supply851 IOhio Pib Ciill1cilll1lI1atibull OIH45245

ToU flmiddotee (800) 755-0516Fax 1513)152-55991

E~Malil ufliledlooltaolcomwwwuflite-a-maticcom

IWwwpmiddotwerlran$ffli$sicmcom WWWge8fI8cllnologycom bull ClEAR TECHNOLOGY JULYAUGUST 2002 15

GROUND GEARS - Ten or Ten ThousandFor small to medium quantities of spurs or helicals that have tomeet close-tolerance AGMA or DIN specs our Reishauer grindersand MampM gear analysis systems are the perfect combination

For Long runs we offer the unique Lieblierr GBN grindingprocess with tull SPC quality control and documentation

So whether your needs are for ten or tens of thousands weinvite you to join the growing list of INSCOcustomers who rely onus for consistent quality reasonable costs and reliable delivery

Q PHONE978-448-6368FAX978-448-5155

nseo 412 Majn~~C=~utiS01450RPORATION

ISO 90011Registered

1 The Best Learning Experience in the Industry

AGMAs 2002

FALL TECHNICAL

MEETING

Find Answers to Your Most Complex TechnicalQuestions

Network with the Best Minds in the Gear Industry

Discover new perspectives and solutions frominternational engineers who are dealing with thesame critical issues that you are

To Register amp For More InformationE-mail techagmaorg Web wwwagmaorg

~ AGl1As Fall TcchnicalMccting A1 V October 20-22 2002 bull St Louis Missouri WI

_____ IIMTS 2002 II1II

2002 SHOW INDilCATES MINIMALRECESSION DAMAGE

Despite the industrys economic hardship projections for theIMTS 2002 Show indicate a relatively normal level of activityEarly figures from AMT reflect that attendance at this years75th anniversary show will be similar in number to the lastshow held in 2000 Approximately 100000 professionals havecompleted the preregistration procedure which is close to the110000 attendees who turned out two years ago Figures for thenumber of international registrants are about equal to that ofthose coming from overseas in 2000

Organizers estimate that $804 million in sales will be trans-acted at this Septembers show which would top the $800 mil-lion reached in 2000

As far as floor space in the exhibit hall there is a 4 percentreduction in the number of exhibits scheduled for Septembersshow However more cancellations and additions of booths-aswell as changes in the size of floor space per company-havetaken place for this years show says John Krisko exhibitionmarketing director

Weve already made over 500 changes Krisko saysWhere weve downsized someone weve upsized someoneelse

Additionally Krisko anticipates a strong showing due to pre-dictions about an upturn in the American economy

Were fortunate that the timing is such that the show willtake place at a time when the business cycle is picking up hesays The IMTSis the indusrys major machine tools show andwill be at the leading edge of the economic recovery

middot1

16 JULYAUGUST 2002 bull GEAR TECHNOLOGY wwwgeartechno1ogycommiddot wwwoowenrensmts stoncom

_ bullbullbullbullbull -IIIMTS2002-----1

FOR EXHIBITS OF THE LATESTGEAR PRODUCTS VISIT THESECOMPANIES bullbullAW Co 71bull a 1IcII TI8ICOW DC Coilia BDam Carp HIlI pound 8eadt __ l1li a _DE-STA-COIWI pound _ HIlic Eampn-TtcII c1W1 pound _RIir AcCl bullbullbull Co II1II nfInI WH a CeIG Hell 7UImo WHIIIII pound _ff6IIIt 8IIItH a CoIG II1II n446- Carp11111 an6- CIIIIII TM c1111 6l1li CoIIIIp lflii pound ZJIIGmtT HIlI 7IJIH8 cw Co II1II pound 2JIZ Vwuhn HIlI

CIIIII HnI pound auJk cw rap WIt H118 _

KlIrtlk HIli bullbull BoodIMKIIfIIr MIrIca LLc HlII _

lIiIIritz Carp 111ft C 5115LiIIIIIIrr 8enr TeeII bull Co II1II _LMJftaIIIIft pound _111M PIle c Hall 7131 FeMraI HIlI DIIIIdriIrrt 0Iic IIIccllicl srJ II1II _MicranIItic T HID 8 _

Mi1Iublsbi HlIVY 1Dd1lllri Hall A 1781Milts a IIIrriII LP HIli B 7144

b USA hIe 11

az-AlIWI NncIIi 1Iecbitd TIdIbullbull Ibull Co II1II _lilawa pmh_ 8IIbtI1lllla _ Ce1IIctAInIMI Dk) a PIIbr _1IIe IIIc 11111 B 721hrticIe In ifill Ce l18li B 7KIRniIIIIHr CarpHIli B 800dt 1133SnnzIr-WnlZlilclllIlr ZInI a Co I HIlI _SIll CIIIIIr Co HnII __ lflii pound ZJIISInr-SU hie HnI _

su anc l1li Hall JIfIWlI c

AurOMATICINSPECIION

- -

trom Ille SourceSiDce 1936 has plOficled the gear industJy

with gear IDspection devices Put your trust in thepeople who invented the process

lvt_t1o FUJI)tI1I111Gbullbull Inpecllon Un 0_11bullbull

11IODUeII~~~uIy AuIomafIC ~bull SofrOAuIomOI ~bull_Oltr_

tor Courw ana r PIIIhGeattbull ~MII PnIICIIIO COaga

For additional Inolmaron on ~IIl11J1l1hlrla andlor Plmatllllla1 ~

lnApaction IIt8Ir oUJ wllbslIe atWWWlWgllaTsJ011m

- ~~CuiliiID-= -- ampfinIUftA

POI~-112Famp raol_~

po rIlIsmssJoncom wltlIlU1rlllchllolollycom bull GEAR TECHNOLOGYmiddotmiddot JULYAUGUST 2002 H

IMTS OFFERS TECHNIICAILCONFERENCEIn addition 10 walking the exhibit floor IMTS attendees have

the option of tiling part in the 60+ conference sessions thatfocu on various manufacturing practices

The categorie offered for the MTS 2002 ManufacturingConference are

Machining-includes emerginglrends andhigh-peed machiningGrinding amp Abrasives~a focus on the latest technoiogiesToolings-se sions on design engineering and rapid rootingQualily-slIategiesandsix sigma applications in manufacturi IIgJob Sbops---concentrating on the unique need of contract andsmall manufacturing operators and~lanufaduring Strategtes=prevides sessions on lean manu-facturing practices advances in manufacturing automation aswell as supply chain and resource management and reels

All of the sessions focus on issues Likeincreasing productiv-ity strategies for reducing lead time tools for assuring qualityand the latest technical developments SME organizers havecheduled speakers who include executives at companies such

as Motorola Inc Visteon Corp and Lean Works IncIn addition to the peeches attendees have the opportunity to

network with other indu try professionals during the technicalconference The intended audience consists of people with man-agement engineering design upervision quality controlhuman resource sales and marketing purcnasing productionoperations and maintenance functions

For jhose holding member hips in SME the conference isfree on September 9 For other cost information visitthe SMEweb ite at wwwsmeorglimts

For more information onme conference schedules for the sixcategorie bull vi itthe mMTShomepage at uwwimtsorg me-mailthe IMTS 2002 ManllfaclUring Conference team at

mfgconfsmeorg

STUDENT SUMMIT INTRODUCES INEXTGENIEIRATIIONITO IMANUFACTURING

The IMTS 2002 Show offers an opportunity for tudents rang-ing from grade school ro college to take part in the exhibition

This opportunity started al the I998 show and attendancerose II by the time of IMTS 2000 according to the IMTSwebsite

Whether these ruderns are college seniors ready to enter theengineering field or in elementary school they will have theopportunity (0 visitthe inside of the booths and speak 10 com-pany representatives to better understand the technology In thepast older students took advantage of this opportunity in

greater number but an ages are invited according to posted sta-tisues on the IMTS website

A goal ofthe student ummit is to introduce the tudents tocareer opportunities ande plain the future of the manufacturingtechnology industry

Teachers and parents are also permitted toparticipate in thestudent summit Show itineraries and assignments are availableto teachers

In 2IXX) atotal of 3923 students were chaperoned throughthe IMTS show by 605 teachers and parents The students andtheir chaperones represented 35 states and 13 foreign countries

Registration is free for the student summit and students mayattend on any day of [MTS

Interested rudents and industries can obtain forms on theIMTS web page For more information call Myrta Mason at(703) 827-5219 or e-mail her at mamasonc1nltonlineorg

Tell Us What YouThink Visit our website al wwwglIrtechnoogycom tobull Rate this articlebull Request more informationbull Conhlet the luthor or complnies mentionedbull Mella I suggestionOr call18471431-i604 to tllk to one of our editors

middot8 JULYAUGUST 2002 GEAR TECHNOLOGY wlllwgtlllflchnoIOfJycom wwwpOWBrlrBfBmission com

IMTS OFFERS TECHNIICAILCONFERENCEIn addition 10 walking the exhibit floor IMTS attendees have

the option of tiling part in the 60+ conference sessions thatfocu on various manufacturing practices

The categorie offered for the MTS 2002 ManufacturingConference are

Machining-includes emerginglrends andhigh-peed machiningGrinding amp Abrasives~a focus on the latest technoiogiesToolings-se sions on design engineering and rapid rootingQualily-slIategiesandsix sigma applications in manufacturi IIgJob Sbops---concentrating on the unique need of contract andsmall manufacturing operators and~lanufaduring Strategtes=prevides sessions on lean manu-facturing practices advances in manufacturing automation aswell as supply chain and resource management and reels

All of the sessions focus on issues Likeincreasing productiv-ity strategies for reducing lead time tools for assuring qualityand the latest technical developments SME organizers havecheduled speakers who include executives at companies such

as Motorola Inc Visteon Corp and Lean Works IncIn addition to the peeches attendees have the opportunity to

network with other indu try professionals during the technicalconference The intended audience consists of people with man-agement engineering design upervision quality controlhuman resource sales and marketing purcnasing productionoperations and maintenance functions

For jhose holding member hips in SME the conference isfree on September 9 For other cost information visitthe SMEweb ite at wwwsmeorglimts

For more information onme conference schedules for the sixcategorie bull vi itthe mMTShomepage at uwwimtsorg me-mailthe IMTS 2002 ManllfaclUring Conference team at

mfgconfsmeorg

STUDENT SUMMIT INTRODUCES INEXTGENIEIRATIIONITO IMANUFACTURING

The IMTS 2002 Show offers an opportunity for tudents rang-ing from grade school ro college to take part in the exhibition

This opportunity started al the I998 show and attendancerose II by the time of IMTS 2000 according to the IMTSwebsite

Whether these ruderns are college seniors ready to enter theengineering field or in elementary school they will have theopportunity (0 visitthe inside of the booths and speak 10 com-pany representatives to better understand the technology In thepast older students took advantage of this opportunity in

greater number but an ages are invited according to posted sta-tisues on the IMTS website

A goal ofthe student ummit is to introduce the tudents tocareer opportunities ande plain the future of the manufacturingtechnology industry

Teachers and parents are also permitted toparticipate in thestudent summit Show itineraries and assignments are availableto teachers

In 2IXX) atotal of 3923 students were chaperoned throughthe IMTS show by 605 teachers and parents The students andtheir chaperones represented 35 states and 13 foreign countries

Registration is free for the student summit and students mayattend on any day of [MTS

Interested rudents and industries can obtain forms on theIMTS web page For more information call Myrta Mason at(703) 827-5219 or e-mail her at mamasonc1nltonlineorg

Tell Us What YouThink Visit our website al wwwglIrtechnoogycom tobull Rate this articlebull Request more informationbull Conhlet the luthor or complnies mentionedbull Mella I suggestionOr call18471431-i604 to tllk to one of our editors

middot8 JULYAUGUST 2002 GEAR TECHNOLOGY wlllwgtlllflchnoIOfJycom wwwpOWBrlrBfBmission com

Chan fertl Inca tc

CHAMFERMAnc INC7842 Burden RoadMachesney Park IL 61115

Tel 815-636-5082Fax 815-636-0075E-mail chamfer96aoLcom

Gear Surface DurabilityDevelopment to Enhance

T PDmiddotransmlSSlon --ower - IensltyJoe Chen John Flynn and Gemiddotoff SemrBUI

New and upgraded transmissions have re-quired a higher input power capability to meet thecustomers expectations Increasing the powerdensity In the transmission gear system wasurgently demanded To shorten the developmentlime in thi area GM Powertrains AdvancedGear Sy tems Group initialed a systematicapproach to evaluate altemarives that had thepotential to meet the needs In addition to a single-tooth bending project for a gear bending fatiguestudy and joint projects with bearing suppliers toimprove the durability of planetary bearings (RefI) a comprehensive gear surface durabilityimprovement project was established

This study is at preliminary assessment of theeffects of applying different design methodolo-gies material selections and manufacturingproce ses on gear surface durability Ba ed on thisanaly is an in-depth study willfellow to furtherunderstand the benefits of using differem alterna-tives for future applications

Objective of tbe Studybull To evaluate and verify the effects of designmaterial selection and manufacturing process onpower density of planetary transmis ion gear etsbull To examine and interpret the effects of factorsuch as surface roughness residual tres coating

material properties and geometry variations ongear urface durabilitybull To understand benefit and risk factors of eachvariant for future application

MetbodologyAll re Is were conducted atthe GM Pewenrain

Gear Laboratory using aback-to-back planetarygear component test machine with a speciallydesigned test fixture (Fig O An existing planetarygear set was chosen as the baseline because itssurface durability characteristics were wellknown and its design permitted easy in pectien

I and maintenance20 JULYAUGUST 2002 bull GEAR TECHNOLOGY wgnrltlchl1olog)lcom bull wwpo rlrll1lmissioncom

IntreductkmGear pitting is one of the primary failure

modes of automotive transmission gear sets Overthe past years many alternatives have beenintended to improve their gear surface durabilityHowever due to the nature of new process devel-opment it takes a length of time and jciot effortsbetween the development team and suppliers toinvestigate and verify each new approach

FiglJre 1 Back-lo-back planetary gear component test ItWcMne and flXllr~

Table 1- Test MaIm lor Surface lJurabilily Comparison

1 B aseline vs IRedesign2 Materiall Selectio~Slln l[jear 110111Use Standard Planets II Ring Gear (orJestingl

Sun Gear MaterialsAISISAE[USAI Steels European Steels

4620M Ba sslin II I 8620 I 9310 I 5120 18COII I 25C04 I 3OC04X X X X X I X I X

3 Mlnufactllring P~DcesslJslllStandard IRing Gear for TestingSun GlIBr Process

Planets Baseline Honed Coating n ual Shot Peening Isotropic 1 Isotropic 2Prod planet X X X XWithout ShotDeburring XHoned X XPlanetsIisotropic 1 Xlsotropic 2 X

The test matrix for the surface durability studyis shown in Table 1 II consists of two differentdesign approaches seven material selections andnine manufacturing processes

Design specifications and stress calculationsare shown in Table 2 The stresses are based on atorque of 1500 N-m at the ring gear Lead taperis not considered in the stress calculations

The test samples were thoroughly inspectedbefore the test Relevant features of each test pariwere identified and recorded for future reference

The gears were originally tested at a constanttorque of ]500 N-m at the reaction arm and aconstant speed of 1500 rpm at the input spindleUnder these conditions however the redesignedgear set did not pit ill a reasonable period of timeand displayed inconsistent failure modesIncreasing the torque to 2000 N-m produced thedesired results

The test matrix was run in a random pattern tosatisfy the statistical requirement for a small sam-ple size The random pattern is also helpful indetecting faults in the machine and fixture set-tings during testing

Failure was achieved when any tooth flankdeveloped a pit with all area of ]0 mm2 at a depthexceeding L5 mm Pit size was measured by acomputerized optical image deviceand pit depthwas assessed with a gear profile inspectionmachine

A Weibun analysis (Ref 2) was performed toestablish life ranks

A metallurgical failure analysis was performedon selected samples for a better understanding ofthe causes of the failure

Test ResultsDesign Appmach The baseline planetary gear

set was designed approximately 20 years ago andhas been used in various transmissions since thenRecently increased engine power and more strin-gent noise specifications caused this design tobecome obsolete A new gear set with enhancedcapabilities but fitting in the same space was thenproduced The design approaches of these twogear systems are quite different The originaldesign used a relatively coarse pitch to enhancethe tooth bending strength and adopted lead taperto reduce the gear force fluctuation

The use of taper moderates vibration levels bypreventing the sudden release of load at the toothtrailing end (Ref 3) The redesign uses a finerpitch to increase both involute and helical contactratios and incorporates profile modifications toOptimize the load distribution Based on 3-B FEA

DesignBase Design IRedesign

Normal Module 1630 1439Gear Ratio 333 329Normal Pressure Angle 2000 1900Helix Angle 1800 2MOTotal Conta ct Ratio 269 363Lead Modification 0-36 um O+-tBjlm

Stress CDmparisonBase Design Redesigll

Bending (MPa 512 513Compressive IMPa 1510 1250

60 BASELINE FINAL DAIVEOUTPUT SPEeo bull APPROX 600-700 RPM1ST ORDER FINAL DRIVECARRIER ROT

20 J

aiBaseline Design

------

Table 2-Design Comparison

60 4T40-E FINgtL ORIVE GEAR GeOMOrRYOUTPUT SPEED APPROX 600-700 RPM1ST ORDER FINAL OArVECARRIER ROT

40

20~ ~

b) Redesign

Jee Chenis a staff project engineerwitt GM Powertrain GearCenter ill Wixom MIHe holds a master of sci-eme degree ill mechanicalengineering as well as amasters degree in businessadministration He hasmore than 25 years ofexperience in gear systemdesign and devetopmeni forallmiddot and off-highwaytransmissions

John Flynnis a senior project engineerwith the GM PowertrainGear Center and the OMPowertrain ApplicariollGroup HI holds a bache-lors degree In memllurgi-cal engineering arId a mas-

ter s degree III businessadministration He liasmore than 11 years ofexperience 111 metallurgicaland failure analysis

Figure 2-Cear noise alia vibration levelcomparisOlImodeling the new design has better load distri-butionand lower overall tooth compressive stressthan the baseline gear set Noise and vibrationtests verified that the new design has a substan-tially lower gear mesh noise level (Fig 2)

As was mentioned above the two designswere tested under different loading conditionsFigure 3 shows the pitting life comparisonbetween the baseline and redesigned gear setsFigure 4 shows the corresponding WeibuU analy-

Geoff Semrauis a senior projectengineerwitn the GM PowertminBase Transmission GroupHe holds a master oj sci-(mce degree i mechanicalengineering He has beenwitl OM Powertrain for 18years and he specializes ingear system developmentand analysis

WWWpow8rtransm estoncom raquo WwwgB8rtBchn0ogycom GEAR TECHNOLOGY JULyAUGUST 2002 21

Gear Surface DurabilityDevelopment to Enhance

T PDmiddotransmlSSlon --ower - IensltyJoe Chen John Flynn and Gemiddotoff SemrBUI

New and upgraded transmissions have re-quired a higher input power capability to meet thecustomers expectations Increasing the powerdensity In the transmission gear system wasurgently demanded To shorten the developmentlime in thi area GM Powertrains AdvancedGear Sy tems Group initialed a systematicapproach to evaluate altemarives that had thepotential to meet the needs In addition to a single-tooth bending project for a gear bending fatiguestudy and joint projects with bearing suppliers toimprove the durability of planetary bearings (RefI) a comprehensive gear surface durabilityimprovement project was established

This study is at preliminary assessment of theeffects of applying different design methodolo-gies material selections and manufacturingproce ses on gear surface durability Ba ed on thisanaly is an in-depth study willfellow to furtherunderstand the benefits of using differem alterna-tives for future applications

Objective of tbe Studybull To evaluate and verify the effects of designmaterial selection and manufacturing process onpower density of planetary transmis ion gear etsbull To examine and interpret the effects of factorsuch as surface roughness residual tres coating

material properties and geometry variations ongear urface durabilitybull To understand benefit and risk factors of eachvariant for future application

MetbodologyAll re Is were conducted atthe GM Pewenrain

Gear Laboratory using aback-to-back planetarygear component test machine with a speciallydesigned test fixture (Fig O An existing planetarygear set was chosen as the baseline because itssurface durability characteristics were wellknown and its design permitted easy in pectien

I and maintenance20 JULYAUGUST 2002 bull GEAR TECHNOLOGY wgnrltlchl1olog)lcom bull wwpo rlrll1lmissioncom

IntreductkmGear pitting is one of the primary failure

modes of automotive transmission gear sets Overthe past years many alternatives have beenintended to improve their gear surface durabilityHowever due to the nature of new process devel-opment it takes a length of time and jciot effortsbetween the development team and suppliers toinvestigate and verify each new approach

FiglJre 1 Back-lo-back planetary gear component test ItWcMne and flXllr~

Table 1- Test MaIm lor Surface lJurabilily Comparison

1 B aseline vs IRedesign2 Materiall Selectio~Slln l[jear 110111Use Standard Planets II Ring Gear (orJestingl

Sun Gear MaterialsAISISAE[USAI Steels European Steels

4620M Ba sslin II I 8620 I 9310 I 5120 18COII I 25C04 I 3OC04X X X X X I X I X

3 Mlnufactllring P~DcesslJslllStandard IRing Gear for TestingSun GlIBr Process

Planets Baseline Honed Coating n ual Shot Peening Isotropic 1 Isotropic 2Prod planet X X X XWithout ShotDeburring XHoned X XPlanetsIisotropic 1 Xlsotropic 2 X

The test matrix for the surface durability studyis shown in Table 1 II consists of two differentdesign approaches seven material selections andnine manufacturing processes

Design specifications and stress calculationsare shown in Table 2 The stresses are based on atorque of 1500 N-m at the ring gear Lead taperis not considered in the stress calculations

The test samples were thoroughly inspectedbefore the test Relevant features of each test pariwere identified and recorded for future reference

The gears were originally tested at a constanttorque of ]500 N-m at the reaction arm and aconstant speed of 1500 rpm at the input spindleUnder these conditions however the redesignedgear set did not pit ill a reasonable period of timeand displayed inconsistent failure modesIncreasing the torque to 2000 N-m produced thedesired results

The test matrix was run in a random pattern tosatisfy the statistical requirement for a small sam-ple size The random pattern is also helpful indetecting faults in the machine and fixture set-tings during testing

Failure was achieved when any tooth flankdeveloped a pit with all area of ]0 mm2 at a depthexceeding L5 mm Pit size was measured by acomputerized optical image deviceand pit depthwas assessed with a gear profile inspectionmachine

A Weibun analysis (Ref 2) was performed toestablish life ranks

A metallurgical failure analysis was performedon selected samples for a better understanding ofthe causes of the failure

Test ResultsDesign Appmach The baseline planetary gear

set was designed approximately 20 years ago andhas been used in various transmissions since thenRecently increased engine power and more strin-gent noise specifications caused this design tobecome obsolete A new gear set with enhancedcapabilities but fitting in the same space was thenproduced The design approaches of these twogear systems are quite different The originaldesign used a relatively coarse pitch to enhancethe tooth bending strength and adopted lead taperto reduce the gear force fluctuation

The use of taper moderates vibration levels bypreventing the sudden release of load at the toothtrailing end (Ref 3) The redesign uses a finerpitch to increase both involute and helical contactratios and incorporates profile modifications toOptimize the load distribution Based on 3-B FEA

DesignBase Design IRedesign

Normal Module 1630 1439Gear Ratio 333 329Normal Pressure Angle 2000 1900Helix Angle 1800 2MOTotal Conta ct Ratio 269 363Lead Modification 0-36 um O+-tBjlm

Stress CDmparisonBase Design Redesigll

Bending (MPa 512 513Compressive IMPa 1510 1250

60 BASELINE FINAL DAIVEOUTPUT SPEeo bull APPROX 600-700 RPM1ST ORDER FINAL DRIVECARRIER ROT

20 J

aiBaseline Design

------

Table 2-Design Comparison

60 4T40-E FINgtL ORIVE GEAR GeOMOrRYOUTPUT SPEED APPROX 600-700 RPM1ST ORDER FINAL OArVECARRIER ROT

40

20~ ~

b) Redesign

Jee Chenis a staff project engineerwitt GM Powertrain GearCenter ill Wixom MIHe holds a master of sci-eme degree ill mechanicalengineering as well as amasters degree in businessadministration He hasmore than 25 years ofexperience in gear systemdesign and devetopmeni forallmiddot and off-highwaytransmissions

John Flynnis a senior project engineerwith the GM PowertrainGear Center and the OMPowertrain ApplicariollGroup HI holds a bache-lors degree In memllurgi-cal engineering arId a mas-

ter s degree III businessadministration He liasmore than 11 years ofexperience 111 metallurgicaland failure analysis

Figure 2-Cear noise alia vibration levelcomparisOlImodeling the new design has better load distri-butionand lower overall tooth compressive stressthan the baseline gear set Noise and vibrationtests verified that the new design has a substan-tially lower gear mesh noise level (Fig 2)

As was mentioned above the two designswere tested under different loading conditionsFigure 3 shows the pitting life comparisonbetween the baseline and redesigned gear setsFigure 4 shows the corresponding WeibuU analy-

Geoff Semrauis a senior projectengineerwitn the GM PowertminBase Transmission GroupHe holds a master oj sci-(mce degree i mechanicalengineering He has beenwitl OM Powertrain for 18years and he specializes ingear system developmentand analysis

WWWpow8rtransm estoncom raquo WwwgB8rtBchn0ogycom GEAR TECHNOLOGY JULyAUGUST 2002 21

The test matrix for the surface durability studyis shown in Table 1 II consists of two differentdesign approaches seven material selections andnine manufacturing processes

Design specifications and stress calculationsare shown in Table 2 The stresses are based on atorque of 1500 N-m at the ring gear Lead taperis not considered in the stress calculations

The test samples were thoroughly inspectedbefore the test Relevant features of each test pariwere identified and recorded for future reference

The gears were originally tested at a constanttorque of ]500 N-m at the reaction arm and aconstant speed of 1500 rpm at the input spindleUnder these conditions however the redesignedgear set did not pit ill a reasonable period of timeand displayed inconsistent failure modesIncreasing the torque to 2000 N-m produced thedesired results

The test matrix was run in a random pattern tosatisfy the statistical requirement for a small sam-ple size The random pattern is also helpful indetecting faults in the machine and fixture set-tings during testing

Failure was achieved when any tooth flankdeveloped a pit with all area of ]0 mm2 at a depthexceeding L5 mm Pit size was measured by acomputerized optical image deviceand pit depthwas assessed with a gear profile inspectionmachine

A Weibun analysis (Ref 2) was performed toestablish life ranks

A metallurgical failure analysis was performedon selected samples for a better understanding ofthe causes of the failure

Test ResultsDesign Appmach The baseline planetary gear

set was designed approximately 20 years ago andhas been used in various transmissions since thenRecently increased engine power and more strin-gent noise specifications caused this design tobecome obsolete A new gear set with enhancedcapabilities but fitting in the same space was thenproduced The design approaches of these twogear systems are quite different The originaldesign used a relatively coarse pitch to enhancethe tooth bending strength and adopted lead taperto reduce the gear force fluctuation

The use of taper moderates vibration levels bypreventing the sudden release of load at the toothtrailing end (Ref 3) The redesign uses a finerpitch to increase both involute and helical contactratios and incorporates profile modifications toOptimize the load distribution Based on 3-B FEA

DesignBase Design IRedesign

Normal Module 1630 1439Gear Ratio 333 329Normal Pressure Angle 2000 1900Helix Angle 1800 2MOTotal Conta ct Ratio 269 363Lead Modification 0-36 um O+-tBjlm

Stress CDmparisonBase Design Redesigll

Bending (MPa 512 513Compressive IMPa 1510 1250

60 BASELINE FINAL DAIVEOUTPUT SPEeo bull APPROX 600-700 RPM1ST ORDER FINAL DRIVECARRIER ROT

20 J

aiBaseline Design

------

Table 2-Design Comparison

60 4T40-E FINgtL ORIVE GEAR GeOMOrRYOUTPUT SPEED APPROX 600-700 RPM1ST ORDER FINAL OArVECARRIER ROT

40

20~ ~

b) Redesign

Jee Chenis a staff project engineerwitt GM Powertrain GearCenter ill Wixom MIHe holds a master of sci-eme degree ill mechanicalengineering as well as amasters degree in businessadministration He hasmore than 25 years ofexperience in gear systemdesign and devetopmeni forallmiddot and off-highwaytransmissions

John Flynnis a senior project engineerwith the GM PowertrainGear Center and the OMPowertrain ApplicariollGroup HI holds a bache-lors degree In memllurgi-cal engineering arId a mas-

ter s degree III businessadministration He liasmore than 11 years ofexperience 111 metallurgicaland failure analysis

Figure 2-Cear noise alia vibration levelcomparisOlImodeling the new design has better load distri-butionand lower overall tooth compressive stressthan the baseline gear set Noise and vibrationtests verified that the new design has a substan-tially lower gear mesh noise level (Fig 2)

As was mentioned above the two designswere tested under different loading conditionsFigure 3 shows the pitting life comparisonbetween the baseline and redesigned gear setsFigure 4 shows the corresponding WeibuU analy-

Geoff Semrauis a senior projectengineerwitn the GM PowertminBase Transmission GroupHe holds a master oj sci-(mce degree i mechanicalengineering He has beenwitl OM Powertrain for 18years and he specializes ingear system developmentand analysis

WWWpow8rtransm estoncom raquo WwwgB8rtBchn0ogycom GEAR TECHNOLOGY JULyAUGUST 2002 21

HiD

18D

16Ct

EE0 if

~g 00

jjbullbullbullbull

IRedJollgl(CAiatJoIIlidi

Figure 3-Sun gear pitting life comparisonbetween designs

9900

9000

5000

if~~~t 1000J

500

1001000 10000 100000

Pitting Failure Hours (gt 10 mmraquo

bull 333 Ratio (wi 1500 Nmiddotm) 329 Ratio (wl2000 Nmiddotm) 329 Ratio (wi 1 500 N-m)~1=3a2 ~1=4415 p=098 ~2=672 ~2 =4828 ~3=672 n8=12748

Figure 4-Weibull allalysis for design comparison

70

~ 60iiiif

50~ECA

40~l 300ofi 20CIEii 10

04620M 8620

Baseline9310 5120 18CD4 25C04 30CD4

Figure S-SZllt gear piuing life camparisonamong materials

MaleriallD

sis result of these two design approaches Theanalysis shows that the baseline coarser pitch sungear has a B-50 pitting life of 40 hours This com-pares to 46 hours at the higher load or 120 hoursat the same load for the finer pitch gear set The120 hours is determined by extrapolation using anSIN curve with slope of 3375 The data indicatethat a significant improvement in pitting life hasbeen achieved by the redesign

Material Selection Seven common gear steelswere selected for surface durability testingFigure 5 shows the surface durability test resultsand Figure 6 shows the Weibull analysis Thesample gears were identical in design and manu-facture Several parameters possibly affectingsurface durability were tabulated Table 3 showsthe chemical composition retained austenitecase depth and hardness of each material Table 4shows a comparison of surface finishes

Manufacturing Processes Seven differentmanufacturing processes were evaluated Bothsun and pinion gears were fabricated using thevarious processes and a total of nine combina-tions were tested (Table I) Standard ring gearswere used for all tests To eliminate unwantedvariations the test gears-except those to behoned-were manufactured and heat treated as asingle lot and later finished by the specificmethod Figure 7 shows the durability life com-parison of the manufacturing processes andFigure 8 shows the Weibull analysis that ranks allthe test variants

The test results reveal that manufacturingprocesses can have a significant effect on the sur-face durability While further investigation isneeded some general observations may be made

The surface finish of the planet pinions has agreat influence on the sun gear durability This isillustrated as follows Honed sun gears run with standard pinions haveonly one-third the life of standard sun gears runwith honed pinions The honed pinions have abetter surface finish than the standard pinionsbull Honed sun gears run with standard pinions haveapproximately one-fourth the life of honed sungears run with honed pinionsbull The shot deburring process which is intendedto remove gear edge burrs and heat-treatmentscale is detrimental to gear life if poorly con-trolled Standard sun gears run with pinionsthat were not subjected to shot deburring havefour times the life of the standard SUll gears runwith pinions that were shot deburred The shotdeburring process produces much rougher sur-

22 JULYAUGUST 2002 GEAR TECHNOLOGY wwwgeartechnologycom wwwpowertrenemisstoricom

faces on the gear teeth arid if not under tightcontrol can cause severe surface damageFigure 10 shows a comparison of gear teethbefore and after a poorly controlled shot debur-ring operation

Both isotropic urface finishing processes(Rd 4) use a sequence of chemkalandmechanical operations to smooth the gear sur-face by removing a few micrometers of materi-al One of these proprietary proces es appearsto have the potential of enhancing surface dura-bility when both mating gears ace treated

Compressive reoidual stres near the toothfillet has long been recognized as contributingto inc rea ed gear tooth bending life The sametheory can also be applied to gear surface dura-bility (Ref 5) with a certain degree of uccessWI is imperative however that the gear surface

not ub tantially damaged by the processused 10 impart that compre sive residual stressFigure 10 how the comparison of the residualstress produced by the conventional and twosecondary proce se The dual shot peening andthe honing process both completed after heattreatment add compressive re idual stress tothe gear surface These stresses will reduce ur-face crack progre ion and thu increase usefulgear life The duaJhol peening requires twodifferent hot size and intensities The coarsershot provides deep penetration at the root andthe finer shot produces high compres ive re id-ual stress close to the surface Similarly thehoaing proce s provide high compressiveresidual stre dose to the tooth surface

All test ariant except the honed paris wereconventionally bobbed and haved and thenbatch heat-treated However tooth profile dis-iortion during heal treatment is not consistentfrom lot to lot or even part 10 part Because thehoning process is completed after heat-treatingbetter profile consistency can be achieved

Table 5 shows a comparison of the profilecontrol obtained by the conventional and hon-ing processes The much improved urfacedurability of the honed sun and planet re 111poundfrom the combination of benefits from con is-tent geometrical control and higher residualcompressive stre s

Gear surface hardness i essential to sustainextended gear life on-metallic coatings canprovide very high surface hardnes (HRc 90)and lower friction coefficients The non-coatedsamples in this studyhad conventional surfaceand core hardness The mechanism by which

l1li00 -QOOO

legend~ I 4620M

i so 00 8620

9310i S 5210~ o 18C04J 25C041000 x

+ 30CDA

500

100100 1000

11LngUft (Hourl ~lOmrnmiddot2IJlSQ

Figure 6-Weibull allalysi for material comparison

Ra(~mlflskV1pm)Rms(~ml

The ~mage surlmiddotece roughnessSkewnm a measure 01 symmetry of vellsys e positive skew indicees e middotpeaky surlaciMWmwn peakI~VIljey heigh OYBthe samplThe rootmiddotmeanmiddotsquare average 01 the measured height deviation taken lIithin the mlul~o area endmeasured from the mean surtace

140

12010l 100eIEct 80F1 60s 40toe

=ii 20

o -- twit 1 D~ MIM

a IIIiiII liIIII

wwwpow9rtransmlssloncom bull WwwIlBSrr8chnologycommiddot GEAR TECHNOLOGY JULVAUGUST 2002 23Figure 7-Momifaclurillg process effectORslm gear pitthlg life

coatings provide improved surface durability isnot fully understood at this time and is the sub-ject of continuing research

figure II shows typical microstructure pho-tographs of tested samples Failure analysisconducted by the GM Pow-ertrain GearLaboratory revealed that most distress is sur-face-initiated fine grain pitting Surface cracksinitiating at inclusions were also found Theinclusions may have been non-metallic impuri-ties in the steel or could have been caused by amanufacturing operation There were also flnd-ings of intergranular oxidation ([GO) related

I

middotbull to the high alloy content of the steel and

I

I improper environment control during heal 1- ---11 bull treatment

Figure8-Weibull analysis for process comparison ir-------------------~----------------------------_ iii

I

I- I

Before Debutg

Ii II~ -

~

II

Aller DebyrrlngI

-lUll

II

~

I1l11Q

~

1D00 10UM 1101l1liPitU1ll1l Flll1 HOllrlgt 1D m ~

- _ 12453 1151 ralS7

+ IIltWDpIo 1 b71B7h7oQO01)_~ DSP amp11b)564 _sol$( _amp11 bampolaquo7~--opIo2 bllltQ74 __

owoPlnlon~ 1l8oL73hio4Ul_IIlt4C_ b1=U2hl0M99_bull __ middotlgtb262ll1l6rzlQOO __ PInIon b501152I6=IlBSl_

Figure 9-Plallet surface roughness before alld aJter sllot deburnng process

-050

Cepth I( mml)

-030-020 000200

-040 -010

10

-200

-400

-600

Honed -800

-1000

-1200

Figure 10-Residual stresses produced by differelll manufacturing processes

ConclusionsTwo similar planetary gear sets wilh different

design approaches were tested to compare surfaceendurance life The redesigned finer pitch gear sethas about three times the Bmiddot50 life of the baselinecoarser pitch gear set

Stress calculations show that the finer pitchgear set has about 21 lower compressi ve stress-es and better load sharing than the baseline coars-er pitcll design The redesigned gear set utilizesfiner pitch to increase the involute and helicalcontact ratios and employs tooth profile modifi-cations to prevent uneven load distribution alongthe line of loath action

Seven different gear steels were tested Allsamples were manufactured and heat-treated byidentical processe WeibuU B-50 lives for sungears between the baseline and the bestperform-ing steel were spread from 18 hours to 37 hoursrespectively The life ranks from the lowe t to thehighest are 4620M (baseline) SAE-93W SAE-5120 SAE-862l 3OCD4 [8CD4 and 25CD4 The last three steels are European products

AJthough the chemical composition surfacefinish and microstructure of these materials wereclosely examined no conclusive explanation oftheir varying urface durability can be made

Iine different manufacturing processes weretested Except for the honed gears all test partswere identically manufactured and heat-treatedSecondary processes were then completed toenhance the power density capability Weibull B-50 lives between the baseline and Ihe best per-forming samples were spread from 95 hours toU5 hours The gear surface lives among the lestvariants are ranked from lowest to highest as fol-lows baseline (standard) process 0) isotropic 1(2) double shot-peened sun gear (3) honed sun

24 JULYAUGUST 2002 bull GEAR TECHNOLOGY wwwgesrtschnologycom wwwpowertransmlssioncom

gear with standard pinions (4) isotropic 2 (5)standard sun gears mated with pillions that werenot shot debarred (6) non-metalliccoated sungear (7) standard sun gears with honed pinions(8) and sun gears and pinions both hailed (9)Among tile characteristics producing significantsurface durability improvement are the surfacefinish the residual stress pattern the surfacehardness and superior tooth geometry control

Planet tooth surface roughne s appears to havea significant effect on the SUIl gear surface dura-bilitymiddotmiddotO

AcknowledgmentsThe accomplishment of this project occurred

through tbe joint efforts of all the project teammembers the manufacturing facility of GMPTmiddotStCatharine and GM Powertrain gear lest and inspec-tion laboratories The authors would also like to

express their appreciation to those who providedassi stance and information to this project

References1 Chen J Planetary eedle BearingDevelopment to Enhance Transmission PowerDensity To be published2 PCmiddot WAS WeibuU AJ1aiysis System User Guidedeveloped by EDS Group March 19933 Hardy A An Action Analysis of Gear TeethWith Modified Lead and Profile SAE 6700504 Hashimoto F Modeling and Optimization ofVibratory Finishing Process Annals of CIPPVol 45 January 19965 Simpson R and R Garibay Quantification ofShot Peening Process Variables AffectingWorkpiece Performance-Process Control andDouble Shot Peening Media SAE-850714

This artlcle was fiirst Ipublished intbeProceedingsohhe International Conference onMechanicall Transmissions heidi in April 20011in Chongqing bullthina

Tell Us Mat Younink VISit wwwlfIChnDlogycomtobull Rate this articlebull Request more informationbull CoAIIct the author or companies mentionedbull Make a suggestionOr call (847)437-amp604 to talk to one of our editors

lal15x Case microstructure to examinelemperedrna rte nsite and retained a ustenite 500~Etchant4 Nital

(b) 500x Core microstructure to examine temperedmartensite and some transformation products500x Etcha lit 4 Nilai

Intergrannlar oxidation and inclusion examlnation nea r ha rdened case area5OOxEtchan 2 Nital

Ie) 10Ci0x

SEM photographs showing the pit examined

Figure l1-Typical microstructure photograph of tested partswwwpow8rlran$missioncom wwwgeartechnoiDgycom GEAR TECHNOLOGY JULYAUGUST 2002 25

ihis papef waspresented althe

JSME InternationalConference on

Motion and PowerIransmissiuns MP12001

in Fukuoka Japan linNovember 2001

Performance Analysis ofHypoid Gears by Tooth Flank

- Form MeasurementIRyohei Takeda Zhonghou Wang

Aizoh Kubo SoichirC1Asano and Shogo Kato

IntroductionThe traditional way of controlling the quality

of hypoid gears tooth flank fonn is to check thetooth flank contact patterns But it is not easy toexactly judge the tooth flank fonn quality by thecontact pattern In recent yearsit has becomepossible to accurately measure the tooth flankform of hypoid gears by the point-to-point meas-uring method and the scanning measuringmethod But the uses of measured data of the

Figure I-Tile scanning measuring method ofhypoid gears

been well developed in comparison with cylindri-cal involute gears In this paper the tooth flankform measurement of generated face-milled gearsface-bobbed gears and Formatereggenerated gearsare reported The authors discuss the advantagesand disadvantages of scanning and point-to-pointmeasuring of 3-D tooth flank forms of hypoidgears and introduce some examples of uses ofmeasured data for high-quality production andperformance prediction

Polnt-To-Puint or Scanning MeasurementThe tradi tional measuring method for the tooth

flank form of hypoid gears is carried out by point-to-point measurement using coordinate measuringmachines (CMMs) That method is used to avoidthe effect of friction between the 3-D sensor probeand tooth flank surface on the measured result

Recently a reliable measuring method by scan-ning the objective tooth flank has been realizedThe scanning measuring machine as shown inFigure I uses a 2-D sensor The negative influ-ence of tooth flank friction on the measuredresults is avoided by control of rotation of the z-axis and by parallel movement of the sensor headposition considering the sensitivity direction ofthe sensor probe and the scanning direction of thetooth flank (Ref 1)

Figure 2 shows how those two kinds of meas-urernentare performed A typical point-to-pointmeasuring pattern is a 5 x 9 grid of the loath flankThese measuring points usually exist well insidethe tip and side edges of the objective tooth flankUsing the scanning measuring method edge-to-edge measurement is possible That measurementcovers all of the tooth flank area including thetooth tip and the area near the toe and heel Thescanning measuring machine that the authors havedeveloped can incorporate various measuring pat-terns For example to simulate gear performancea pattern of 29 lines of profile and one line of lead

Figure 2-Two kinds of measuring methods for lIypoid gears or a pattern of three lines of profile and three lines26 JULYAUGUST 2002 GEAR TECHNOLOGY wwwgeartechnologycommiddot wwwpowartransmissioncom

Point-te-Pcint Measurement

Touch points on the grid

Proilelengthwise

Yd = Constantx

Smiddotcanning Measurement

Trace lines

5 points9 PQill$

ScanningProfile MaxLead Max 9 lines

113 points per line29Unes

how far the form is from its true surface which of hypoid gear is performed using tooth surfacewould realize conjugate motion Tile same is true geometry calculated by the tooth cutting machineof cylindrical involute gears That mean we can setting parameters for bothring gear and pinionuse the experience of cylindrical involute gears Figure 6(a) hews an example of tooth contactfor designing and manufacturing hypoidgears analy is of Gleason Hehxformreg hypoid gearsand the measured data of the gear el can be used (gear et 1 shown in Table I) by direct approachat any stage of designing or manufacturing (Gleason TCA) Using the concept of the conju-

is president of Asmlo GearDirect prediclioll of contact pattern gate tooth flank forms of mating gears and com- Co ua of Osaka Japan

from measured reslIlts Figure 4 shows an po ite error surface (Ref 2) a simulation pro- which manufactures Mears

example of the output forms of measured results gram for predicting the gear performance was and gear unhs

from the conjugate approach for a Formaereg developed Figure 6(b) is an example of the out- Dr Shogo Katohypoidgear set Here the ring gears measured put of simulated results by conjugate approach Ir senior 1fWIJrCh(r ill

curve i hown by seningit to the po Won of coo- for the same gears under tile same condition The Asalla Gears eIIRt1eerlgdepartment 11 1979 hetact corresponding to thaI of the measured pinion results of (a) and (b) agree well when the samelie veloped principles for

Because the conjugate pinion tooth flank form is mounting position (VIH valuerts given 10011 profile m1fISIIYIm111I

incorporated for reference in defining the tooth of hypoiti gearswwwpowerlansmlssioncom bull W gfNrschnologycom GEAR TECHNOLOGY JULYAUGUST 2002 27

of lead are usually incorporated Each line hasInmeasuring points

Figure 3 compares data of a tooth flank formmeasured by boih the scanning and point-to-pointmethod The objective 100111 Hank form hassome waviness (high-frequency components)That waviness was found (0 be the main cause ofunpleasant gear noise The scanning method candetect the detail of a tooth flank form but thepoint-to-polnt method could not do so

Two Kinds Of Method-S 110 DefmeReference Tooth Su-rface

Direct approacf (Machire setling base]Existing CMMs normally incorporate the nomi-nal surface calculated by cutting machine settingparameters and cutter geometry for both ring gearand pinion as the reference surface to define toothflank form deviation It is good in practice 10check whether the tooth cutting i performed CO[-

reetly 01 not But hypoid gears are heat treatedusually case hardened and then lapped Allerheat treatment or lapping tooth surfaces are dis-torted or deformed from that of the cutting stageThat mean gears have lost their datum and it istherefore often not useful to mea lire the toothflank form deviation of hypoid gears according tothe reference based on We machine setting

Conjugate approach In the case of the scan-ning method the reference tooth surface of ringgears is calculated by cutting machine settingparameters just like tile former case However forthe pinion the conjugate surface to the ring gearurface i u ed Inthis case two reference sur-

faces can rotate theoretically without motionerror

The conjugate surface of the pinion i a virtu-aJ one If l1Iepinion and gear teeth are measuredusing such a conjugate approach the measuredvalues of the flank form deviation would show

55 fz component

ijI~ r

F bullSo olllP ib~- i1 bmpla o1llnullil~lti

4 BySClnning rTJiIsurinliimMhi

IOrdr tQllb mesbing 1rI1(mcy

I) Mulrd res1101 vibration bllMeasurd curn ollootll ID~form

Figure 3-Difjerence ill vibrational stale oj gears IIIlIel tootlljlallkjorm de vi-alUms base dlfjertflt high frequency componelll bull alld tile comparoOll 0 tootllfll1II1cormmeasured by poirlt-to-poillt d canllirlg melmasor Ial ca_I

PiniQo1W-h bullbull ll

Pinion tWh bullbull 11]Prm

nl tOI

Pnlfl-Iifd_middotwidtbl

~nr __bull

1bullbull 1bnk Drwh bullbull r

PromIU11

IhRIICooe loath

Flrltt- Itnk 0pllo

Figure 4-Measuled tooti profill alld teod [ormo[ Gleason jace-milledFiirmalelgenerated gear set expressed n malillg state

flank form deviation every poinl on both curves Ryohei Takedal f is general manager ill rilecorresponds to contact From this presentation or

system engineering deptri-mea ured re ul bull we therefore can directly see i1Ifl (if Osako Seimilfll

the contact position of tooth flank of actual gears Kiwi Co Ltd Jocmld ill

on the measured curves=that is we can directlysee the outline of the tooth flank contact patternMeasurement of Gears from DLfIcRol Tooth

Cutting MethodsThe scanning method is capable of measuring

tooth flank form deviation of hypoid gear beingcut by different cutting methods igure 5(a)shows a sample of measured results (rom a gen-erated face-milled gear set and Figure 5(b) showsthat of a face-bobbed spiral bevelgear set

Tooth Contact Analysis Under No LoadConventionally tooth contact anaJysis (TCA)

Osaka Japoraquo HI is ill

ciJarge of technical delmiddotelopmiddotmelll nJ the (atfl)(III_~1$ searmeasuring machines

Dr Zhonghou wangif a consultant for NihonParametric Technology I(Kof Tokyo As (l doctoral stu-dau Ire did a Sillily on per-fonnance anotysis ana simu-mimr of ttypoid Rears

Prof DrEng Aizoh Kllbolbelol1gs to tht jacullY atKyoto Univer iry 1poundlaltd illKyoto Japan He lorb inthe precision engineerillgdeportment wrkllinrllarestlu lJeifomrance ofInmiddotIJUidlbelmiddote gems

AI the first stage of hypoid gear development

cutting machines for pinion teeth are adjusted to

get the optimum tooth contact pattern as seen inFigure 6(b) Figure 7 shows the simulated effect

of a change in pinion cutting conditions In this

case a 60 bias-in change is given according to

the Gleason cutting sheet (Summary)

By this change the path of contact (the trace

of dots in the figure) is inclined and the contact

pattern becomes longer but the contact positionis shifted in the toe direction In this case the

mounting position should therefore be adjusted toget the contact pattern in the middle of the moth

HankTooth Contact Analysis of Actual Gear

Using the conjugate approach tooth contactanalysis of actual hypcid gears based on the

measured tooth flank form data becomes easyAn example of analysis of acrualgears that had

tooth wear problems in the field is discussed inthe fol1owing sections

No load analysis The sample gear set usedinFigures 8-10 is gear set 2 il] Table 1 Figure 8(a)

shows the composite error surface for the theoret-ical tooth flank form calculated from the machinesetting parameters for ring gear and pinion That

surface is expressed by the form deviation curveon each contact line neglecting its actual length

The contact lines are set in the direction of theprogress of gear mesh and the composite errorvalues are plotted on these contact lines Thelength of contact line near toe and heel of a toothis stretched which differs from the actual state But by this expression the contact point of toothflanks can be more vividly recognized The effectof topremreg is well recognized from the figure

Topremreg is a protuberance on the hypoid cuttingblade that produces an undercut on the gear being

cutFCQm Figure 8(a) we can directlypredict the

contact pattern under no-load conditions to someextent Figures 8(b) and 8(c) show the path-of-

contactpeint and contact pattem expressed on the

ring gear tooth flank under no load Figure 8Cd)shows the motion curve (transmission error) forthis case

This gear set has experienced trouble with

tooth flank wear Figure 9 shows the state of theinitial tooth flank le of fresh gears just pro-duced in terms of measured composite error sur-face observed no-load contact pattern obtainedon the meshing frame (rolling tester) andthe no-

load contact pattern calculated by using the meas-ured tooth flank form data (Ref 4) The transmis-sion error calculated for no-load conditions by

28 JULYAUGUST 2002middot GEAR TECHNOLOGV bull wwwgeartschnologycom wwWpowsftransmssoncom

~f~lLJ No 01 teeth

tlllll

~ M~I~ hce WidthlVmiddot 250mm Pinion Ofbet

_ 5jt millinal bullbull at PLniQP

almiddotGI ganraledgenerated hnoid gelt

pm li-itr

rbullbullfiLud

Figure 5 Measured tooth klnk form of gears of different cutting metJOds

Tooth contllc pattern

- _L--

Motion CUIflI8

Vill IJ~113 (mm)a) Direct approlch (Gleason TCA)

rl~~

1 ~If ~it

C~ntaclPlttem

1--- - j TraRmission Errllf

j __ M~~ ~ liiim~J u - -

bull --11 I - --------ViIl= 1)081113 (mm)

Figure 6-TCA of direct approach amI conjugaleapproach

Contac Pattern amp Plm 01ColIIId

fI Trusmission Enor(Tooh Harmonics)

u IIJ

1-uuu bullOJ -

II J J r

of F F

Figure Simuiation for pilliol CUttilig ehanglaquo(conjugate approacll)

using measured tooth flank form is also hownFigure ]0 shows those aspects for the worn toothHan~ of thetroubled gear U ually the mountingpo ition of hypoid gears normally expressed by(V H) value is different at lapping at the loathcontact pattern checking on a rolling tester and inan actual gearboxs assembled condition This dif-ference leads to the same kind of difficulty in car-rying out the simulation using the measured dataof tooth flank form deviation of hypoid gears Inthe simulation some adjustment of (V H valuesfrom those nominal mounting di Lances (V n 0)at designing or 011 the rolling tester is usually nec-essary to obtain the nearest contact patternbetween observed and imnlated figures

On load analysis Figure 11 shows the com-parison between the mea ured and simulated con-tact patternunder load andthe transmission errorfor that case Figure l 2 shows the distribution ofnormal load flash temperature a) and Hertzianstress on the tooth flank

Flash temperature Tf (in degree ) is obtained asa function of the flash temperature index Tr bythe followjng equation

T = Til (U 1~ J1t rpm30) J A P c

where ~ = functional coefficient of tooth flankrpm rotational speed of pinion A = normal con-ductivity p = specific weight and c = specificheat

The sample gear set I ed in Figures 11 and ]2i gear et 3 in Table 1 Figure 13 compare the imulated FEA calculated and measured tooth fil-let stre s (Ref 6) for gear et 4 from Table 1FigureI3(a) hows the changing stale of tooth fil-let stress with the progress of meshing at threelongitudinal fillet positions along the tooth widthie at 116 from toe 12 from toe and 56 from toe

Figure l3(b) arranges the same resultsm theform of fillet stress distributionalong looth widlhThese figures for tooth fillet stress showa goodagreement amongthe FHA mea ured and simu-lated results Figure 14 shows a simulated fre-quency component of vibrational excitation forgear set 2 in Table 1 using measured tooth flankform deviation of the initial gear flanks shown inFigure 8 The vtbrational excitation is calculatedin terms of the tooth meshing frequency compo-nents The actual frequency component in Hem(lIs) of the vibrational excitation caused by thetooth me hing of these hypoid gears can be wellpredicted from these results and the driving speedof this gear set in operation AIl of these quantitiesconcerning the performance of gears aresimulat-ed-calculatedat tile same time This is an extraor-

Figule tJ-Composite e17Orsurjace path ocontaci point and red COltad pal-tem expressed 011 the ring gear tootllJlaJlk (JOT geaTS cut by standard machinesettiJlg summary data and V=OOOmm H=OOO rnm)

-------Uh A A Ilit~~~ ---- _ I00ltI1

Figur-e 9-Composite eorjlrmk

G~l---

-~---V--I - -(VI N~ I

Figure UJ-Composite error surface tmd red corltact pat1em for worn jlal bullk oftroubled gears dinarily big difference from conventional methodsof hypoid gear designing and load carrying capac-ity calculation

U iug mea ured tooth flank form deviation andthe performance simulation software the per-formance of bypoid gear with actual tooth flankforms under certain gear alignment conditions canbe well predicted at the designing stage and in thecase of troubleshooting

Taking an example of tooth flank wear troublementioned in the No load analysis section thevibrational excitation is calculated with theprogress of tooth flank wear as shown in Fig-ureIS We can predict how tile vibrational excitationof hypoid gears changes with long-running usage(Ref 5)

ConclusionsThe merit of quality control of hypoid gears by

measuring the tooth flank form is discussed Thescanning measuring method can realize tooth end-to-end mea urement which is very effective forknowing tile detailed condition of the gear toothA performance simulation program ofhypoid

wwwpowlfrtrnsmissloncom wwwgurt9chnotogycommiddot GEAR TECHNOLOGVmiddotmiddot JULYAUGUST 2002 29

II 1

I i t-------+--t---I---r-+----~

L---------PROURE$$ OF M~SHING

d Simulted IrlInmiui de 10 d

_ImiddotSimultdl bullbull llt1l potlom

Figure11 LJaded contact pattern OIl ring gear flank and tile transmissionerror (inpllt torque raquo 30 N-m)

Figure l2-Simulaled stress stale on tootiflank of lJypoid gears

l60 --FU---+---- Appnmmlloa- It 116

o 02 04 06 08 1Toe Becl

(I) Compooi aml FEA M d d oIullldfiUet strcs distributiQf1 with tJK progtcu of meshing

(b) Coolpri __ EA MU1Dd oM oimuIltdmaximum fillet WCII distribution at ODJ toodl width

Figure 13 Ring gear tooth fillet stress (torque sraquo 777 Nvm)

e~ 6egl cuIlt11amp1

Abscissa is the ordertOI Imeshing frequency

Figure U-Remlt of the vibrational excitation

e~Ieltgt

c~u~eQ

1i0gt WEAR SiAGE

Figure 15-Cllallge of the mesh iug frequellcy COlllpOllelltof Jlibratiollal exci-tation williprogress of tootiJ flank wear

Figures in Fig 6Fig 7Which Gear

I Set Was UsedI

Fig 8 Fig 9Fig 10 Fig 14

Fig 15

Fig II Fig 12 Fig 13

30 JULVAUGUST 2002 GEAR TECHNOLOGY wwwgearrechnologycom wwwoowertrensmtsstoncom

gears that can accept measured form deviation ofreal tooth flank form is developed The gear per-formance-such as transmission error contactpattern under load and no load normal loaddistribution on tooth flank contact stre toothfillet stress flash temperature and vibrationalexcitation for actual production gears-can nowbe analyzed Some simulated results are com-pared with actual results in the field and fromexperience Also the effectiveness of the meas-urement of tooth flank form accuracy of hypoidgears is discussed 0

ReferencesI Saito Y er al Check of 3D Fonn Aocuracy ofHypoid amp Bevel Gear Teeth for the New Generation ofQuality Contra] AGMA Fall Technical Meeting 19982 Kubo A et al A Computer Based Approach forEvaluation of Operating Performance of Bevel andHypoid Gears lSME International Journal (SeriesC) Vol40 No4 1997pp 749-7583 Kagimoto Het al Development of ToothSurface Measuring Machine for Hypoid GearsToyota Motor Co Technical Review Vol 43 No LMay 1993pp 112-1l74 Wang Zhonghou A Kuboet aI Simulation ofDeterioration of Hypoid Gear Performance due toTooth Flank Wear (I st Report Data Processing ofMeasured Tooth Flank Wear) Transactions of theJapan Society of Mechallical Engineers Vol66 No647 2000 pp 2354-23625 Wallg Zhonghou A Kubo et al Simulation ofDeterioration of Hypoid Gear Performance due 10

Tooth flank Wear (2nd Report Model for Tooth flankWear and the Change ofGerur Performance ResultedTransactions of the Japan Society of MechanicalEngineers Vol66 No 647 2000 pp 2363-23706 Wang Zhonghou A Kubo et al Tooth RootStress Analysis of Hypoid Gears (2nd ReportIntroduction of Predicting Method for the ToothRoot) Transactions of the Japan Society ofMechanical Engineers Vol 66 o 652 December2000 pp 221-2277 Wang Zhonghou A Kubo et al Measurement of3D Tooth flank Form of Hypoid Gears and its Usagefor High Quality Production and PerformancePrediction International Conference on MechanicalTransmissions Chongqing China April 200 1

Tell Us What You Think Visit wwwgesttechnologycomtobull Rate this articlebull Request more informationbull Contact the author or companies mentionedbull Make a suggestionOr call (8471437-6604to talk to one of our editors

Sponsored by theAmerican Gear Manfacturers Association

Greater Columbus Convention CenterColumbus OhioOctober 26 - 292003

- -

_-------------INDUSTRYNIEWS-------------

a manufacturer of aero-Paul D Lefitf space gearbox assem-blies mechanical actuators detail gear-ing and complex precision machinedcomponents for commercial and militaryaircraft systems

Lefief has held numerous seniormanagement positions [or defense andcommercial manufacturing companiesincluding DaimlerCb1Ysler

One of Leflers goals will be to gainadditional market share in the UnitedStates Europe and Asia

Caratron Industries Inc has been awholly-owned subsidiary of Belgium-based BMT nv since 2000

32 JULYAUGUST 2002 bull GEAR TECHNOLOGY wwwgeartmiddotechITologycom wwwpowerlraITsmissloncom

Gleason Corp Appoints VicePresident and CFO

John 1 Perrotti was named executivevice president and CFO of RochesterNr-based Gleason Corp

He has been with Gleason since 1986in a variety of positions and has servedon the board of directors since 2000

Perrotti holds memberships in severalprofessional organizations including the

Association for Manufacturing Technol-ogy and the Financial ExecutivesInstitute A CPA he has degrees from theUniversity of Rochester and RochesterInstitute of Technology

Mahr Federal Appoints New VPMahr Federal Inc of Providence

RI appointed Patrick Nugent as vicepresident of metrology systems

Precision Made - Cost EffectiveOne Statement with Two Objectives

Dragon Precision Tools from KoreaNoticeable Different Clearly Superior

DRAGON PRECISION TOOLS CO LTDRepresented Exclusively in the USA by

440331003821135 Lorain Road

Fairview Parkt OH 44126Fax 4403310516

httpwwwgallencocomhttpwwwdragoncokr

Nugent most recently worked in themetrology systems customer solutionsgroup for Mahrs parent company MahrGmbH of Gottingen Germany Prior tothat he served in numerous engineeringcapacities for Cummins Engine Co

Among his new responsibilities areleading the systems business develop-ment and furthering profitable growth inthe North American marketplace

Philadelphia Gear Hires New CFOPhiladelphia Gear

Corp of Norristown PAhired Stephen Verger asCFO

Among his responsi-Steplen Vergel bilities will be leading anaccounting financial analysis and treas-ury functions for the company He alsowill design Philadelphia Gears evolvingbusiness model which is focused onspeciali zed gear aftermarket service andmarine propulsion drives

For the past 23 years Verget hasworked as a finance leader at EJDuPont de Nemours of Wilmington DEin a number of roles including CFOpositions in agricultural biotechnologyand advanced materials

New President and CEONamed atCaratron IndUstries

Paul D Lefief wasnamed president andCEO of Caratron Indus-tries Inc of Warren MI

_-------------INDUSTRYNIEWS-------------

a manufacturer of aero-Paul D Lefitf space gearbox assem-blies mechanical actuators detail gear-ing and complex precision machinedcomponents for commercial and militaryaircraft systems

Lefief has held numerous seniormanagement positions [or defense andcommercial manufacturing companiesincluding DaimlerCb1Ysler

One of Leflers goals will be to gainadditional market share in the UnitedStates Europe and Asia

Caratron Industries Inc has been awholly-owned subsidiary of Belgium-based BMT nv since 2000

32 JULYAUGUST 2002 bull GEAR TECHNOLOGY wwwgeartmiddotechITologycom wwwpowerlraITsmissloncom

Gleason Corp Appoints VicePresident and CFO

John 1 Perrotti was named executivevice president and CFO of RochesterNr-based Gleason Corp

He has been with Gleason since 1986in a variety of positions and has servedon the board of directors since 2000

Perrotti holds memberships in severalprofessional organizations including the

Association for Manufacturing Technol-ogy and the Financial ExecutivesInstitute A CPA he has degrees from theUniversity of Rochester and RochesterInstitute of Technology

Mahr Federal Appoints New VPMahr Federal Inc of Providence

RI appointed Patrick Nugent as vicepresident of metrology systems

Precision Made - Cost EffectiveOne Statement with Two Objectives

Dragon Precision Tools from KoreaNoticeable Different Clearly Superior

DRAGON PRECISION TOOLS CO LTDRepresented Exclusively in the USA by

440331003821135 Lorain Road

Fairview Parkt OH 44126Fax 4403310516

httpwwwgallencocomhttpwwwdragoncokr

Nugent most recently worked in themetrology systems customer solutionsgroup for Mahrs parent company MahrGmbH of Gottingen Germany Prior tothat he served in numerous engineeringcapacities for Cummins Engine Co

Among his new responsibilities areleading the systems business develop-ment and furthering profitable growth inthe North American marketplace

Philadelphia Gear Hires New CFOPhiladelphia Gear

Corp of Norristown PAhired Stephen Verger asCFO

Among his responsi-Steplen Vergel bilities will be leading anaccounting financial analysis and treas-ury functions for the company He alsowill design Philadelphia Gears evolvingbusiness model which is focused onspeciali zed gear aftermarket service andmarine propulsion drives

For the past 23 years Verget hasworked as a finance leader at EJDuPont de Nemours of Wilmington DEin a number of roles including CFOpositions in agricultural biotechnologyand advanced materials

New President and CEONamed atCaratron IndUstries

Paul D Lefief wasnamed president andCEO of Caratron Indus-tries Inc of Warren MI

bull INDUSTIRVNEWS _

Bodycote~sIlansing Pilant ReceivesBorgWarner Certification

80rgWamer Automotive of Chicagoa selected Bodyeote of Lansing MIfor the Zero Defect Supplier Award forthe second eonsecutive year The awardwas presented at a recent ceremony inChicago Bodycote Lansing is an ISO9000- OS 9000- and Ford Ql-apprevedfacility

Bodycote Lansing specializes inbalch atmospheric heat treating and saltpot processes The facility also has anextensive vibratory eleening capabilityA focus at the plant is Bodycote propri-etary ferritic nitrocarburizing proee called Linduretrade

The Lansing plant is part of a five-plant network in Michigan BodycoteNorth America Inc is a subsidiary ofBodycote International plc located illMacclesfield England

INew Sales Manager for IGregAllen Co

Janice Thoma wasappointed ales and ourc-ing manager for the gearcutting tools product lineof Greg Allen Co located

JQnic~ TlIol1llD in Fairview Park OHHer new re pon ibibties include man-

aging and directing a nationwide net-work of sales representatives and coor-dinating with global suppliers

For the past 22 years Thomashasworked iathegjebal gear tool industry Since 1994 she has been the US salesengineer for David Brown Gear Tools ofHuddersfield UK

Birchmere Capital and Wildeir-Deem Buy Miner Centrifugal

Casting CoMiller Centrifugal Casting Co

(MCC) a foundry in Cecil PAt wasbought by Birehmere Capital LP ofPittsburgh PAt and Wilder-Deem ofNew York NY

MCC manufactures finish-machined

throughoul North America Additionallyit is a supplier of copper-based centrifu-gal castings having patented thebimetallic casting process used in thewonn gear business

Tile Birehmere fund targets acquisi-tionsm middle market manufacturingdistribution service and financial com-panies Wilder-Deem is a financial con-sulting and investment firm whose other

steel-related holding is Damascus SteelCastings of New Brighton PAO

rail U What You ink bullyllit~bull RIll middotRIquaI Ibull ConIacthe cOIIp IIIIIIDIIIIIOrCII fI

[Q)~[]I ~amptreg ~____ Ipreciaianllhlaugh diamondl

INNOVATIVE PCD REINFORCINGFOR DIRECT PLATED DRESSERS

We will design build and guarantee from your gear summary charts gear dressers forRaisbauer SPA and Fassler DSA Syste~irectmiddotPlated or SinteredmiddotBond Single- orDouble-Sided Dressers

WE also p~oducegear dressers ferbull Gleason TAG

Gleason IPfauterII Gleasoll PhoenilC

middotUebherrmiddotIKlingelnbergbull Oerlikon-Opalbull Hoeflerbull Hllrlllibull Kapillbull Nilesbull SampuJensm Mikron Maagbull CS8p8~

We oHer eur customersbull IHighest Accuracy bull Competitive Prices Fastes11DeIivery IRelap II Reptating Service

Call or fax us your gear dresser requirementsYou will quickly discover what leading US gear producers have learned

DR KAISER gear dressers Ire the best value availableDiltributH by

SLMunson~ Company

401 Hug St Columbia SC 2IZ01Phon 1-11JOn5-1390 FIX 1-8D3-IZ9-Oi01E-mail infoOllmulIIOlIcomferrous and non-ferrous centrifugal cast-

ings for equipment manufacturers andlong product steel rolling facilities

po ~rtrnmll$$IOIlcom bull glrIlchnoloQycom bull GEAR TECHNOLOGY JULYIAUGUST 2002 33

A Defiinitive SnurcebuekforTransmission Engiineers

PROCEEDINGSInternational Conference on Gears

Munich March 13-115201)2 Two volumes VDI-BerichteNo 1665 edited by VOIi Association of German EngineersVOl Society for Development Design and Distribution1198 pages numerous figures and tables format 14B emsx 21 cms ISBN 3-18-091665-6 List price 14400euro

More than 80 richly illustrated contributions fromrenowned Gierman and international experts cover theentire spectrum of design construction and applicatinnof all types of gears These two volumes present the lat-est state of technology to the expert reader in RampDindustry and academia

VIOl VerlagOrders VDI Verlag Ms PetroKoetherPOB 101054 10-40001 OiisseldorfIGermanv fax +49-211-61881JJE-Mail pkoethervdi-nachrichten comWebsite hHplwwwvdi-literaturde

SPIRAL IBEVEIL GEARS(Transmissions )

Spiral amp Straight Bevel Gear ManufacturingICommercial to aircraft quality gearing

Spurhelicalsplinedi shafts linternal amp externallshaved amp ground gears Spirai bevel grinding

IMidwest Transmissions 81Reducers ISO compliiant

MIDWESTGEARM -I WE~IlOOlL IINC

NMiI d ~ ~Wa rren MI 4I11III9

CONTACTICRAIG D ROSS-(586) 754-8923

IfAX (586) 754~B926

bullbullbull _TECHINICAL CAIlENIDAR bullbullbull _July 15-17-Powder MetaUurgy Basic Shert Cour e PennStater Conference Center Hotel State College PA This confer-ence will focu on the history of PfM different designs in com-pacting tools the use of sintering in developing functional prop-erties injection molding of metal powder M-P[F standards spe-cial tests for powders and the latest high-tech PIM technologies$1125 lor APMI members and MP]F member companyemployees $1325 for nonmembers For more iaformation con-tact the Metal Powder Industries Federation by telephoneat(609) 452-7700 or by fax at (609) 987-8523

July lS-19-8asic Gear Manufacturing Course DaleyCollege Chicago IL Offering hands-on training in gearing andnomenclature principles of inspection gear manufacturingmethods and hobblog and shaping Open to sales reps techni-dans executives managers machinists quality managers andengineers $650 tor AGMA members $775 for nonmembersFor more information contact AGMA by telephone at (703)684-0211 or bye-mail atjentressagmaorg

September 4--11-futernational Manufacturing TechnologyShow McConnick Place Chicago IL Spon ored by AMT- TheAssociation for Manufacturing Technology See our coverage onpages 12-18 or visit wwwimtsnetorg

September 11-l3-Basic Gear Noise Short CoullSe OhioState University Columbus OH Attendees willlearn to designgears to minimize the major excitations of gear noise transmis-sion error dynamic friction forces and shuttling forcesExtensive demonstrations of special gear analysis software willtake place in addition to showcasing of OSU gear test rigsParticipants are invited to discuss their specific gear and trans-mission noise concerns $12501 For moremforrnation contactOSU by telephone at (614) 292-5860 or on the Internet atwwwgearlaborg

September 11-I3-Fundamentals of Gear Design UniversityCenter for Continuing Education University of Wisconsin-Milwaukee Milwaukee WI This course will provide attendeeswith a beginning knowledge of modem gear system design andanalysis A knowledge of geometry trigonometry and elemen-tary algebra is required $10195 For more information contactthe University Center for Continuing Education by telephone at(414) 227-3100 or visit the centers web pages viawwwuwmedu

Tell Us What YouThink V1Sit www~comtobull Rate tIIis colbull Request iRIDnutionbull Ccmtect lite orgbullbull izIIIioIII mentionetIbull Make a suggestionOr call IB471aHamp04 to talk to ORB of our editorsl

34 JULYAUGUST 2002 bull GEAR TECHNOLOGY wwwgeartechnologycom wwwpowertrensmlssion com

A Defiinitive SnurcebuekforTransmission Engiineers

PROCEEDINGSInternational Conference on Gears

Munich March 13-115201)2 Two volumes VDI-BerichteNo 1665 edited by VOIi Association of German EngineersVOl Society for Development Design and Distribution1198 pages numerous figures and tables format 14B emsx 21 cms ISBN 3-18-091665-6 List price 14400euro

More than 80 richly illustrated contributions fromrenowned Gierman and international experts cover theentire spectrum of design construction and applicatinnof all types of gears These two volumes present the lat-est state of technology to the expert reader in RampDindustry and academia

VIOl VerlagOrders VDI Verlag Ms PetroKoetherPOB 101054 10-40001 OiisseldorfIGermanv fax +49-211-61881JJE-Mail pkoethervdi-nachrichten comWebsite hHplwwwvdi-literaturde

SPIRAL IBEVEIL GEARS(Transmissions )

Spiral amp Straight Bevel Gear ManufacturingICommercial to aircraft quality gearing

Spurhelicalsplinedi shafts linternal amp externallshaved amp ground gears Spirai bevel grinding

IMidwest Transmissions 81Reducers ISO compliiant

MIDWESTGEARM -I WE~IlOOlL IINC

NMiI d ~ ~Wa rren MI 4I11III9

CONTACTICRAIG D ROSS-(586) 754-8923

IfAX (586) 754~B926

bullbullbull _TECHINICAL CAIlENIDAR bullbullbull _July 15-17-Powder MetaUurgy Basic Shert Cour e PennStater Conference Center Hotel State College PA This confer-ence will focu on the history of PfM different designs in com-pacting tools the use of sintering in developing functional prop-erties injection molding of metal powder M-P[F standards spe-cial tests for powders and the latest high-tech PIM technologies$1125 lor APMI members and MP]F member companyemployees $1325 for nonmembers For more iaformation con-tact the Metal Powder Industries Federation by telephoneat(609) 452-7700 or by fax at (609) 987-8523

July lS-19-8asic Gear Manufacturing Course DaleyCollege Chicago IL Offering hands-on training in gearing andnomenclature principles of inspection gear manufacturingmethods and hobblog and shaping Open to sales reps techni-dans executives managers machinists quality managers andengineers $650 tor AGMA members $775 for nonmembersFor more information contact AGMA by telephone at (703)684-0211 or bye-mail atjentressagmaorg

September 4--11-futernational Manufacturing TechnologyShow McConnick Place Chicago IL Spon ored by AMT- TheAssociation for Manufacturing Technology See our coverage onpages 12-18 or visit wwwimtsnetorg

September 11-l3-Basic Gear Noise Short CoullSe OhioState University Columbus OH Attendees willlearn to designgears to minimize the major excitations of gear noise transmis-sion error dynamic friction forces and shuttling forcesExtensive demonstrations of special gear analysis software willtake place in addition to showcasing of OSU gear test rigsParticipants are invited to discuss their specific gear and trans-mission noise concerns $12501 For moremforrnation contactOSU by telephone at (614) 292-5860 or on the Internet atwwwgearlaborg

September 11-I3-Fundamentals of Gear Design UniversityCenter for Continuing Education University of Wisconsin-Milwaukee Milwaukee WI This course will provide attendeeswith a beginning knowledge of modem gear system design andanalysis A knowledge of geometry trigonometry and elemen-tary algebra is required $10195 For more information contactthe University Center for Continuing Education by telephone at(414) 227-3100 or visit the centers web pages viawwwuwmedu

Tell Us What YouThink V1Sit www~comtobull Rate tIIis colbull Request iRIDnutionbull Ccmtect lite orgbullbull izIIIioIII mentionetIbull Make a suggestionOr call IB471aHamp04 to talk to ORB of our editorsl

34 JULYAUGUST 2002 bull GEAR TECHNOLOGY wwwgeartechnologycom wwwpowertrensmlssion com

middotmAmfrlA featureaOur CNC hobbIng machines coverthe ful spectrum of gears up to adiameter of 4500 mm Over 1000installations of this machine con-cept testify to its acceptanceCouple all this with over 50 yearsof experience and support andyour choice for gear hobbing hasto be Liebherr-SIGMAL POOLnGNmgP~~~ ond 0erIiIlt0n

See Us AtliMTS BOOTIH 704011B

lLiebl1en Gear Technology Co11465Woodland DriveSaline M148H6-12S97344297225middot Fax73442912294intolgtliebherrcom

bull 1 TECHNOLOGY FOCUS

IntrnductionCarbon steels have primarily been used

to manufacture aerospace gears due to thesteels mechanical characteristics Analloyed low carbon steel is easily case-hardened to obtain a hard wear surfacewhile maintaining the ductile core charac-teristics The microstructure achieved willaccept the heavy loading shocks and ele-vated temperatures that gears typicallyexperience in applications The carbonsteel machinability allows for generalmachining practices to be employed whenproducing aerospace gears versus the moreadvanced metal removal processesrequired by stainless and nickel-basedalloys

As a consequence of using non-stain-less steel for gears in-process corrosion(rust and chemical attack) of gears is possi-ble during the manufacturing processSurface corrosion of carbon steel gears andshafts can lead to unacceptable stress risersin the material if action is not taken toremove the surface pitting and neutralizethe cause Once the corrosion effect beginsit wilLI continue to attack the grain bound-aries of the material The result is reducedmechanical properties of the alloy that canlead to component failure at performancelevels wellbelow typical operating condi-tions

Prior to this project the corrosion prob-lem was minimized by the use of oil-basedpreservatives and rust-inhibiting machin-ing coolants However as the negativeeffect on exposed production workers andthe environment was better understoodand with disposal costs escalating the gearmanufacturing industry changed to water-based coolants and degreasingagents This

Miinimizatioln of in-ProcessCorrosion of Aerospace Gears

Son Nguyen AIi Manesh Jim~ Reeves and Danny Mahan

I

I Factors Level = + Level = U r

I A Condition Virgin HeclaimedI B Alloy Pyrowear 53 9310

I

C HT Condition Carburized Core Materia1o Exposure Time 90 Minutes 30 Minutes

I E Coolant Concentration 8 1F Coolant Temperature 150degF iOdegF

I G Coolant Type Synthetic Soluble Oil

A B C 0 E F1

G EG I Hours to Initiation i

middot1 1 1 1 1 1848 II I

1middot1 middot1 middot1 1

1848

I -1 1 I 1 I -1 - - 847I

I middot1 I -1 I 1 I middot1 -t 841 I 1 ---1 middot1 - - 841

middot1 - I 1 -1 1847-

I -I 1 1 -1 - 1843 - 1 -t 1 - -1 - 1843

-1 I I1- - II - 1 -1 -1 - 1843

middot1 middot1 -1 -r 1 - -I 843I-

I-t -I 1 1 -1 i

-t 1842-1 I 1 1 middot1 -1 I -1 1842

middot1 1 I 1 1 middot1 middot1 middot1 BOI

middot1 - middot1 1 1 middot1 -1 middot1 18nt1 -1 middot1 1 middot1 middot1 1395

I

I

1 middot1 1 1 - middot1 1394 I

I 1 1 1 1 I 1 middot1 I 1392

II-

I1 1 middot1 1 1 - middot1 1392i I middot1 1 1 - 1392I I-

I

I

I I 1 1 -1 1 - 1392 II

I1 1 1 -1 1 1 - -1 1392

I--~

1 1 -t -1 1 -t middot1 1392I 1 -1 -t -1 1 1 -I -1 1392I I

II

1 -I 1 1 1 1 middot1 - 1338I

i

I

I

-1 -1 1 1 -1 1 -1 1 1319 I 1

IImiddot1 middot1 middot1 1 I middot1 1 1 1319 I

1 1 1 middot1 1 I middot1 -1 1224 Treatment Run Example I middot1 1 1 1 1 I middot1 -1 1220 II middot1 1 middot1 middot1 1 I middot1 1 1204

i

Figure i-Partial Experimental Matrix With Screen in Anal sisg y36 JULYAUGUST 2002 GEAR TECHNOLOGY wwwqe srtecnnotoqvcom raquo wwwpowerrransmission ccm

This project was conducted in two ph as- lion) were selected from two separate geares Phase [ was to identify root causes of in- manufacturers as aresult of the processprocess eorrosion by conducting a compre- mapping described above These parts pro-hensive study using manufacturing process vided he basi for detailed evaluations ofbench marking at two gear production the signilicant manufacturing steps thatfacilities The Phase ~ ludy was augment- were likely to initiale in-process corrosion Jim Reevesed by controlled hlbomtory eX-PeriIllents [II addition parts selected were made cut is manager of proce s engineering QI HontywellThe desired end product of Phase I was ta of common base materials mat are widely Engine Systems and Services Gear

understand the sources 10[ corrosion an used in the aerospace industry te manufac- Mamljaclurilg Center of Excellence jl Phoenix AZ He lias worked for HOl1eywell since 980

gears during the manufacturing proces and ~ (Ore gears The materials selected were wilen he starred as a grilldillg operator Reeves10 identify solution to minimize the corm- 9310 (AMS6260 AMS6265) and Pyre- is a ctmifitd six sigma blackbelt

sian problem Phase D was to implement i wear X-53 (AMS6308) steels

the identified solutions to a restricted area l When the part selection and verifica- ~~ic~~~rfor lhl manufacturing Itchof the maaufacnmng floor to test them in a lion of me manufacturing steps were com- nologydivision of lrrRl He holds a doctorareproduction environment pletedthe FMEA was used to evaluate the in engifeeringfrom Michigan Stale Ulliversity

Phase [ involved defining the bound- process inputs The F1vfEAsallowed the His work includes projects for INFAC flIt

aries of the gear making process develop-I teamto prioritize processillputs that could instrumented factoryfor gears

ing detailedprocess Imps that describe all contribute to COIro ion ini~iation Proces Daony IMahanof me steps required to produce the gears I connol charts and the f1vfEA were used to worked at lite US Army Aviatioll GIld Missileverifying the acmal inputs at each process identify and rank the suspect inputs lobe Command ill Redsone Arsenal AL as a super-tep and perfomting he fmure mode and I tested visor 0 manufacturing Scit11C1 and ttChnolog)

IilWwpowBrlransmlssiMcom wreJrtecftnologycommiddot OEAR lECHINOLOGY bull JULYAUGUST 2002 31

shift was immediately followed by anincrease inrust The result was more eostlygears from increased rework scrappedgears increased preventative activities andmanufacturing How inefficiencies due toout-or-sequence proces ing The replace-ment of corroded gears created additionaldelays Corrosion of gears in the manufae-niring environmem continued to plague theentire gear industry therefore an investiga-tion to minimize he corrosive effect waswarranted

OlljootivesThe objective of hi project were to

identify the root causes of the observed in-process corrosion of gears and to developpreventative practices to mitigate its occur-renee during the manufacturing of gears

Specifically me objectives werebull Utilize advanced manufacturing toolsuch as tati tically designed experiments

process How charts and failure modes andeffect analysi (FMEA) to systematicallymdy the potential causes of the in-process

cerro ion bull Evaluate the impacts of chemical attackand residual coolant on corro ion includ-ing the investigation of an adapted on-lineDigi-Galv probe as a predictive toolbull Identify and implement preventive prac-tices to reduce in-proces corrosion

Approacb Scope and Methodology

TECHINIOLOGY FOCUS

Normal Probability Plot ot theStandardizedl Effacts(Response s Tim to Alpha QI10)

IF-~----------------IA A ConditionB BAlloyC C HT Conditio0 D MinuteE E COnCentl8lonF F TemperatureG G Coolant Type

2

01

-11

EG

01Standardized Effect

Figurt 2 Normal ProbabililJ Pl)teffects analysis (FMEA) to assess priorityof the process parameters After theprocess conditions that could potentiallybe contributing to corrosion initiation wereidentilied and prioritized the design ofexperiments were planned and performed

For the proce s mapping the boundaryof the rudy was established from rawmaterial handling through fmal inspectionof the part Typical eianutacturiag processstep for gears included turning cutnnghobbing deburring grinding bullheat treating(Cu platingcarburizing tripping) lap-ping shot peening and inspection Threegear parts (spurhelical and planetary pin-

SooT Nguvenlis a system control engineer at Upper OccoquanSewage AIlhorit) He is working on a $200 milmiddotlion plant expansion project He was a eniorengineer al the liT R~learch huriwle (lrml)from 1999-2001

TECHNOLOGY IFOCUS

Normal Probability Plot of the Standardized Effects(Response is Time to Alpha = 010 Only 30 Largest Eflieets Shownl

A AConditionBBAlloyC C HI ConditionD 0 MinuteE E ConcentrationF FlemperatllreG G Coolant Type

fEG

DbullC

ACEADDD

fAEDE

~DoBf

IfHBDBC

BFaADAB

CCDBDSf8E~c-CG --CEOf

After a comprehensive investigationthe coolant was identified as one of the keyprocess inputs that may be contributing tocorrosion initiation Multiple potential fail-ure modes were identified for the coolantalong with multiple possible interactionsKey factors identified after control chartand FMEA analyses were coolant concen-tration coolant temperature exposure time

coolant type coolant contamination and

material heat treat conditionOnce the team had narrowed the list of

potential corrosion initiation factorsthefirst DOE design trategy began Thestrategies for the design and factor levelsettings are detailed in Figure 1 Factorsselected for testing are (A) coolant condi-tion (virgin and reclaimed) (B) specimenalloy (Pyrowear X-53 and 9310) (C) spec-imen heat treat condition (carburized anduncarburized) (D) exposwe time tocoolant (90 and 30 minutes) (E) coolant

concentration (8 and 1) (F) coolanttemperature ([5oP and 7oPF) and (G)coolant type (synthetic and soluble oil)Refractometer readings were used as ameasure of coolant concemration

Phase II commenced in parallel with theDOEs as information became available

from Phase I to speed up the verification ofbenefits resulting from implementation ofthe identified solutions Examples of the

success of this approach were the imple-mentation ofa new coolant in one gearfacility and the resolution of the chemicalattack problem noted on the gear line

Discussion of ResultsThe DOEs were conducted at

Honeywell Engines amp Systems facilityThe steel specimens were subjected to pre-scribedconditioas identi fled in Figure 1-An example of a treatment run in thematrix was to soak a carburized PyrowearX-53 specimen in an 8 concentration vir-gin soluble oil coolant at 70F for 30 min-utes The specimens were then loaded intoa humidity chamber that was set at 80PFand a relative humidity level of70 Thesesamples were monitored twice daily forcorrosion initiation When corrosion initia-tion (response) occurred ihe time (hours)to initiation was recorded and used for theexperimental analysis

38 JULYAUGUST 2002 GEAR TECHNOLOGY wwwgeartechnoJogycommiddot wwwpowertransmJss oncom

6 12o 2 4

Figure 3-Paleto of Effects

Interaction Plot ~Data Means) for Time to Initiation-1 1 middot1 r -1 -1 1 middot1 I -1

1500~_JI ~

1000500

1500

~ lt 1000 I500

1500

~ ~1000

-- 5001500

--- ~1000

500 1500

- nne-- ---1 c 5001500

FTemperitllre

~- 10001I 500

G Coolan-1 I

A CQd~in1

-A-B Allcy -I 9bull 1

1111-1

C HT Condo middot1bullI

1middot1

0 Minutes Ex I -

middotmiddot1 _-

IIIE Concentration1 -

_ Figure 4-1llteractioll Plot

Main iEffeets Plot ([lata Means) forlime to Initiation

~eEB

~

Figure 3-Main Effects Plot

Upon e IJtbli rung the hours to eorro- (93]0 and Pyrowear X-53) degreasing sol- replaced by a pray or quick immersionsion initiation on (he specimens analysesof the experiment results were performedAcreening analy is was performed byolting the hours 10 initiation in ascendingorder and evaluating tile experimentmatrix for any pattern The visual patternshown in Figure I that appeared 10 be ig-niflcam i coelam type coolant condj-tion and an interaction between eoolaruconcentration and coolant type A taJisli-cal aaalysis was next performed The nor-mal probability plot and the Pareto ofeffects shown in Figure 2 and Figure 3respectively identified the same facto asbeing significant Figure 4 the interactionplot howed the coolant type by coolantconcentration as the mo t significantinteraction in the model The main effectspI t Figure 5 indicated that coolant con-centration and coolant type had the great-est effect An analysis of variance(ANOVA) confirmed the re uljs reportedabove as statistical I) ignificam Based ontile data virgin and low concentrationcoolants are predicted to initiate corrosionmore quickly than reclaimed and highercoacentration coolants

Heal treat condition alsoaffected theinitiation of corm ion in that rugh carbon(carburizeCl) urface were more resi tanl110 initiation as compared 10 core (unear-burized) wfaces It was also ynthesizedfrom the data set hat u edreclaimedcool ants offered better corrosion resi tanceIhltlll the virgin mix in both synthetic andsoluble oil eoolants The data also suppon-ed using the soluble oil cool ani as the pre-ferred cutling fluid As a result of the

experiment the soluble oil water-basedcoolant was implemented in the gear pro-duction area as part of Phase n work

Based 011 the results of the first DOEthe trntegy fOJ the second experiment wasdeveloped The factors selected for Ihi experiment were ceolant concentration(3 and 6) base material magnetism (0

gall sand 10gauss) pecimen una ~ fin-i h (6 Ra and 36 Ra) iron particlesincoolant (clean coolant and panicles 8i ded)specimen raw material heat lot (heat lots 1and 2) specimen heat treat condition (car-burizedand uncarburized) pecimen alloy

vent condition (virgin and used) and pre-servative oil application (four-minute soakapplication and pray application) At heIlggestion of manufacruringpersonnel the

additional factor that was added tn jhe

DOE was the method of preservative oilappli alion Previou process mappinganalysis revealed that a lypical lot of gearscoald go through the preservauve soakcycle 24 limes If the soak cycle could be

with the arne result significant sBvingsincycle time and cost could be realized

With the factors and level middotettingsestablished the DOE was execUled asdescribed previously However there was

no corrosion initiation observed on tilsamples after six months The experimentindicated that the factors te ted would n t

initiate corm ion provided a c tiIq ofpreservative oil was applied regardle of

THE PURDYCOPORArION

150 9002 CERnFIED

S86 Hilliard Stree~ PO BOJ U198 Manchester CT 06045-1898 USATelephone 860 649-0000 bull Fax 860645middot6293

Home Page httpwwwpurrfytransmissionsromf-Mail salespurdytransmlssonscom

Cll19B TgtI II_~11OII

WW pOWllrnmluUMcom bull g middotchnologycom bull GEAR TECHNOLOGY JUl YAUGUST 2002 39

This project was conducted in two ph as- lion) were selected from two separate geares Phase [ was to identify root causes of in- manufacturers as aresult of the processprocess eorrosion by conducting a compre- mapping described above These parts pro-hensive study using manufacturing process vided he basi for detailed evaluations ofbench marking at two gear production the signilicant manufacturing steps thatfacilities The Phase ~ ludy was augment- were likely to initiale in-process corrosion Jim Reevesed by controlled hlbomtory eX-PeriIllents [II addition parts selected were made cut is manager of proce s engineering QI HontywellThe desired end product of Phase I was ta of common base materials mat are widely Engine Systems and Services Gear

understand the sources 10[ corrosion an used in the aerospace industry te manufac- Mamljaclurilg Center of Excellence jl Phoenix AZ He lias worked for HOl1eywell since 980

gears during the manufacturing proces and ~ (Ore gears The materials selected were wilen he starred as a grilldillg operator Reeves10 identify solution to minimize the corm- 9310 (AMS6260 AMS6265) and Pyre- is a ctmifitd six sigma blackbelt

sian problem Phase D was to implement i wear X-53 (AMS6308) steels

the identified solutions to a restricted area l When the part selection and verifica- ~~ic~~~rfor lhl manufacturing Itchof the maaufacnmng floor to test them in a lion of me manufacturing steps were com- nologydivision of lrrRl He holds a doctorareproduction environment pletedthe FMEA was used to evaluate the in engifeeringfrom Michigan Stale Ulliversity

Phase [ involved defining the bound- process inputs The F1vfEAsallowed the His work includes projects for INFAC flIt

aries of the gear making process develop-I teamto prioritize processillputs that could instrumented factoryfor gears

ing detailedprocess Imps that describe all contribute to COIro ion ini~iation Proces Daony IMahanof me steps required to produce the gears I connol charts and the f1vfEA were used to worked at lite US Army Aviatioll GIld Missileverifying the acmal inputs at each process identify and rank the suspect inputs lobe Command ill Redsone Arsenal AL as a super-tep and perfomting he fmure mode and I tested visor 0 manufacturing Scit11C1 and ttChnolog)

IilWwpowBrlransmlssiMcom wreJrtecftnologycommiddot OEAR lECHINOLOGY bull JULYAUGUST 2002 31

shift was immediately followed by anincrease inrust The result was more eostlygears from increased rework scrappedgears increased preventative activities andmanufacturing How inefficiencies due toout-or-sequence proces ing The replace-ment of corroded gears created additionaldelays Corrosion of gears in the manufae-niring environmem continued to plague theentire gear industry therefore an investiga-tion to minimize he corrosive effect waswarranted

OlljootivesThe objective of hi project were to

identify the root causes of the observed in-process corrosion of gears and to developpreventative practices to mitigate its occur-renee during the manufacturing of gears

Specifically me objectives werebull Utilize advanced manufacturing toolsuch as tati tically designed experiments

process How charts and failure modes andeffect analysi (FMEA) to systematicallymdy the potential causes of the in-process

cerro ion bull Evaluate the impacts of chemical attackand residual coolant on corro ion includ-ing the investigation of an adapted on-lineDigi-Galv probe as a predictive toolbull Identify and implement preventive prac-tices to reduce in-proces corrosion

Approacb Scope and Methodology

TECHINIOLOGY FOCUS

Normal Probability Plot ot theStandardizedl Effacts(Response s Tim to Alpha QI10)

IF-~----------------IA A ConditionB BAlloyC C HT Conditio0 D MinuteE E COnCentl8lonF F TemperatureG G Coolant Type

2

01

-11

EG

01Standardized Effect

Figurt 2 Normal ProbabililJ Pl)teffects analysis (FMEA) to assess priorityof the process parameters After theprocess conditions that could potentiallybe contributing to corrosion initiation wereidentilied and prioritized the design ofexperiments were planned and performed

For the proce s mapping the boundaryof the rudy was established from rawmaterial handling through fmal inspectionof the part Typical eianutacturiag processstep for gears included turning cutnnghobbing deburring grinding bullheat treating(Cu platingcarburizing tripping) lap-ping shot peening and inspection Threegear parts (spurhelical and planetary pin-

SooT Nguvenlis a system control engineer at Upper OccoquanSewage AIlhorit) He is working on a $200 milmiddotlion plant expansion project He was a eniorengineer al the liT R~learch huriwle (lrml)from 1999-2001

TECHNOLOGY IFOCUS

Normal Probability Plot of the Standardized Effects(Response is Time to Alpha = 010 Only 30 Largest Eflieets Shownl

A AConditionBBAlloyC C HI ConditionD 0 MinuteE E ConcentrationF FlemperatllreG G Coolant Type

fEG

DbullC

ACEADDD

fAEDE

~DoBf

IfHBDBC

BFaADAB

CCDBDSf8E~c-CG --CEOf

After a comprehensive investigationthe coolant was identified as one of the keyprocess inputs that may be contributing tocorrosion initiation Multiple potential fail-ure modes were identified for the coolantalong with multiple possible interactionsKey factors identified after control chartand FMEA analyses were coolant concen-tration coolant temperature exposure time

coolant type coolant contamination and

material heat treat conditionOnce the team had narrowed the list of

potential corrosion initiation factorsthefirst DOE design trategy began Thestrategies for the design and factor levelsettings are detailed in Figure 1 Factorsselected for testing are (A) coolant condi-tion (virgin and reclaimed) (B) specimenalloy (Pyrowear X-53 and 9310) (C) spec-imen heat treat condition (carburized anduncarburized) (D) exposwe time tocoolant (90 and 30 minutes) (E) coolant

concentration (8 and 1) (F) coolanttemperature ([5oP and 7oPF) and (G)coolant type (synthetic and soluble oil)Refractometer readings were used as ameasure of coolant concemration

Phase II commenced in parallel with theDOEs as information became available

from Phase I to speed up the verification ofbenefits resulting from implementation ofthe identified solutions Examples of the

success of this approach were the imple-mentation ofa new coolant in one gearfacility and the resolution of the chemicalattack problem noted on the gear line

Discussion of ResultsThe DOEs were conducted at

Honeywell Engines amp Systems facilityThe steel specimens were subjected to pre-scribedconditioas identi fled in Figure 1-An example of a treatment run in thematrix was to soak a carburized PyrowearX-53 specimen in an 8 concentration vir-gin soluble oil coolant at 70F for 30 min-utes The specimens were then loaded intoa humidity chamber that was set at 80PFand a relative humidity level of70 Thesesamples were monitored twice daily forcorrosion initiation When corrosion initia-tion (response) occurred ihe time (hours)to initiation was recorded and used for theexperimental analysis

38 JULYAUGUST 2002 GEAR TECHNOLOGY wwwgeartechnoJogycommiddot wwwpowertransmJss oncom

6 12o 2 4

Figure 3-Paleto of Effects

Interaction Plot ~Data Means) for Time to Initiation-1 1 middot1 r -1 -1 1 middot1 I -1

1500~_JI ~

1000500

1500

~ lt 1000 I500

1500

~ ~1000

-- 5001500

--- ~1000

500 1500

- nne-- ---1 c 5001500

FTemperitllre

~- 10001I 500

G Coolan-1 I

A CQd~in1

-A-B Allcy -I 9bull 1

1111-1

C HT Condo middot1bullI

1middot1

0 Minutes Ex I -

middotmiddot1 _-

IIIE Concentration1 -

_ Figure 4-1llteractioll Plot

Main iEffeets Plot ([lata Means) forlime to Initiation

~eEB

~

Figure 3-Main Effects Plot

Upon e IJtbli rung the hours to eorro- (93]0 and Pyrowear X-53) degreasing sol- replaced by a pray or quick immersionsion initiation on (he specimens analysesof the experiment results were performedAcreening analy is was performed byolting the hours 10 initiation in ascendingorder and evaluating tile experimentmatrix for any pattern The visual patternshown in Figure I that appeared 10 be ig-niflcam i coelam type coolant condj-tion and an interaction between eoolaruconcentration and coolant type A taJisli-cal aaalysis was next performed The nor-mal probability plot and the Pareto ofeffects shown in Figure 2 and Figure 3respectively identified the same facto asbeing significant Figure 4 the interactionplot howed the coolant type by coolantconcentration as the mo t significantinteraction in the model The main effectspI t Figure 5 indicated that coolant con-centration and coolant type had the great-est effect An analysis of variance(ANOVA) confirmed the re uljs reportedabove as statistical I) ignificam Based ontile data virgin and low concentrationcoolants are predicted to initiate corrosionmore quickly than reclaimed and highercoacentration coolants

Heal treat condition alsoaffected theinitiation of corm ion in that rugh carbon(carburizeCl) urface were more resi tanl110 initiation as compared 10 core (unear-burized) wfaces It was also ynthesizedfrom the data set hat u edreclaimedcool ants offered better corrosion resi tanceIhltlll the virgin mix in both synthetic andsoluble oil eoolants The data also suppon-ed using the soluble oil cool ani as the pre-ferred cutling fluid As a result of the

experiment the soluble oil water-basedcoolant was implemented in the gear pro-duction area as part of Phase n work

Based 011 the results of the first DOEthe trntegy fOJ the second experiment wasdeveloped The factors selected for Ihi experiment were ceolant concentration(3 and 6) base material magnetism (0

gall sand 10gauss) pecimen una ~ fin-i h (6 Ra and 36 Ra) iron particlesincoolant (clean coolant and panicles 8i ded)specimen raw material heat lot (heat lots 1and 2) specimen heat treat condition (car-burizedand uncarburized) pecimen alloy

vent condition (virgin and used) and pre-servative oil application (four-minute soakapplication and pray application) At heIlggestion of manufacruringpersonnel the

additional factor that was added tn jhe

DOE was the method of preservative oilappli alion Previou process mappinganalysis revealed that a lypical lot of gearscoald go through the preservauve soakcycle 24 limes If the soak cycle could be

with the arne result significant sBvingsincycle time and cost could be realized

With the factors and level middotettingsestablished the DOE was execUled asdescribed previously However there was

no corrosion initiation observed on tilsamples after six months The experimentindicated that the factors te ted would n t

initiate corm ion provided a c tiIq ofpreservative oil was applied regardle of

THE PURDYCOPORArION

150 9002 CERnFIED

S86 Hilliard Stree~ PO BOJ U198 Manchester CT 06045-1898 USATelephone 860 649-0000 bull Fax 860645middot6293

Home Page httpwwwpurrfytransmissionsromf-Mail salespurdytransmlssonscom

Cll19B TgtI II_~11OII

WW pOWllrnmluUMcom bull g middotchnologycom bull GEAR TECHNOLOGY JUl YAUGUST 2002 39

TECHNOLOGY IFOCUS

Normal Probability Plot of the Standardized Effects(Response is Time to Alpha = 010 Only 30 Largest Eflieets Shownl

A AConditionBBAlloyC C HI ConditionD 0 MinuteE E ConcentrationF FlemperatllreG G Coolant Type

fEG

DbullC

ACEADDD

fAEDE

~DoBf

IfHBDBC

BFaADAB

CCDBDSf8E~c-CG --CEOf

After a comprehensive investigationthe coolant was identified as one of the keyprocess inputs that may be contributing tocorrosion initiation Multiple potential fail-ure modes were identified for the coolantalong with multiple possible interactionsKey factors identified after control chartand FMEA analyses were coolant concen-tration coolant temperature exposure time

coolant type coolant contamination and

material heat treat conditionOnce the team had narrowed the list of

potential corrosion initiation factorsthefirst DOE design trategy began Thestrategies for the design and factor levelsettings are detailed in Figure 1 Factorsselected for testing are (A) coolant condi-tion (virgin and reclaimed) (B) specimenalloy (Pyrowear X-53 and 9310) (C) spec-imen heat treat condition (carburized anduncarburized) (D) exposwe time tocoolant (90 and 30 minutes) (E) coolant

concentration (8 and 1) (F) coolanttemperature ([5oP and 7oPF) and (G)coolant type (synthetic and soluble oil)Refractometer readings were used as ameasure of coolant concemration

Phase II commenced in parallel with theDOEs as information became available

from Phase I to speed up the verification ofbenefits resulting from implementation ofthe identified solutions Examples of the

success of this approach were the imple-mentation ofa new coolant in one gearfacility and the resolution of the chemicalattack problem noted on the gear line

Discussion of ResultsThe DOEs were conducted at

Honeywell Engines amp Systems facilityThe steel specimens were subjected to pre-scribedconditioas identi fled in Figure 1-An example of a treatment run in thematrix was to soak a carburized PyrowearX-53 specimen in an 8 concentration vir-gin soluble oil coolant at 70F for 30 min-utes The specimens were then loaded intoa humidity chamber that was set at 80PFand a relative humidity level of70 Thesesamples were monitored twice daily forcorrosion initiation When corrosion initia-tion (response) occurred ihe time (hours)to initiation was recorded and used for theexperimental analysis

38 JULYAUGUST 2002 GEAR TECHNOLOGY wwwgeartechnoJogycommiddot wwwpowertransmJss oncom

6 12o 2 4

Figure 3-Paleto of Effects

Interaction Plot ~Data Means) for Time to Initiation-1 1 middot1 r -1 -1 1 middot1 I -1

1500~_JI ~

1000500

1500

~ lt 1000 I500

1500

~ ~1000

-- 5001500

--- ~1000

500 1500

- nne-- ---1 c 5001500

FTemperitllre

~- 10001I 500

G Coolan-1 I

A CQd~in1

-A-B Allcy -I 9bull 1

1111-1

C HT Condo middot1bullI

1middot1

0 Minutes Ex I -

middotmiddot1 _-

IIIE Concentration1 -

_ Figure 4-1llteractioll Plot

Main iEffeets Plot ([lata Means) forlime to Initiation

~eEB

~

Figure 3-Main Effects Plot

Upon e IJtbli rung the hours to eorro- (93]0 and Pyrowear X-53) degreasing sol- replaced by a pray or quick immersionsion initiation on (he specimens analysesof the experiment results were performedAcreening analy is was performed byolting the hours 10 initiation in ascendingorder and evaluating tile experimentmatrix for any pattern The visual patternshown in Figure I that appeared 10 be ig-niflcam i coelam type coolant condj-tion and an interaction between eoolaruconcentration and coolant type A taJisli-cal aaalysis was next performed The nor-mal probability plot and the Pareto ofeffects shown in Figure 2 and Figure 3respectively identified the same facto asbeing significant Figure 4 the interactionplot howed the coolant type by coolantconcentration as the mo t significantinteraction in the model The main effectspI t Figure 5 indicated that coolant con-centration and coolant type had the great-est effect An analysis of variance(ANOVA) confirmed the re uljs reportedabove as statistical I) ignificam Based ontile data virgin and low concentrationcoolants are predicted to initiate corrosionmore quickly than reclaimed and highercoacentration coolants

Heal treat condition alsoaffected theinitiation of corm ion in that rugh carbon(carburizeCl) urface were more resi tanl110 initiation as compared 10 core (unear-burized) wfaces It was also ynthesizedfrom the data set hat u edreclaimedcool ants offered better corrosion resi tanceIhltlll the virgin mix in both synthetic andsoluble oil eoolants The data also suppon-ed using the soluble oil cool ani as the pre-ferred cutling fluid As a result of the

experiment the soluble oil water-basedcoolant was implemented in the gear pro-duction area as part of Phase n work

Based 011 the results of the first DOEthe trntegy fOJ the second experiment wasdeveloped The factors selected for Ihi experiment were ceolant concentration(3 and 6) base material magnetism (0

gall sand 10gauss) pecimen una ~ fin-i h (6 Ra and 36 Ra) iron particlesincoolant (clean coolant and panicles 8i ded)specimen raw material heat lot (heat lots 1and 2) specimen heat treat condition (car-burizedand uncarburized) pecimen alloy

vent condition (virgin and used) and pre-servative oil application (four-minute soakapplication and pray application) At heIlggestion of manufacruringpersonnel the

additional factor that was added tn jhe

DOE was the method of preservative oilappli alion Previou process mappinganalysis revealed that a lypical lot of gearscoald go through the preservauve soakcycle 24 limes If the soak cycle could be

with the arne result significant sBvingsincycle time and cost could be realized

With the factors and level middotettingsestablished the DOE was execUled asdescribed previously However there was

no corrosion initiation observed on tilsamples after six months The experimentindicated that the factors te ted would n t

initiate corm ion provided a c tiIq ofpreservative oil was applied regardle of

THE PURDYCOPORArION

150 9002 CERnFIED

S86 Hilliard Stree~ PO BOJ U198 Manchester CT 06045-1898 USATelephone 860 649-0000 bull Fax 860645middot6293

Home Page httpwwwpurrfytransmissionsromf-Mail salespurdytransmlssonscom

Cll19B TgtI II_~11OII

WW pOWllrnmluUMcom bull g middotchnologycom bull GEAR TECHNOLOGY JUl YAUGUST 2002 39

Upon e IJtbli rung the hours to eorro- (93]0 and Pyrowear X-53) degreasing sol- replaced by a pray or quick immersionsion initiation on (he specimens analysesof the experiment results were performedAcreening analy is was performed byolting the hours 10 initiation in ascendingorder and evaluating tile experimentmatrix for any pattern The visual patternshown in Figure I that appeared 10 be ig-niflcam i coelam type coolant condj-tion and an interaction between eoolaruconcentration and coolant type A taJisli-cal aaalysis was next performed The nor-mal probability plot and the Pareto ofeffects shown in Figure 2 and Figure 3respectively identified the same facto asbeing significant Figure 4 the interactionplot howed the coolant type by coolantconcentration as the mo t significantinteraction in the model The main effectspI t Figure 5 indicated that coolant con-centration and coolant type had the great-est effect An analysis of variance(ANOVA) confirmed the re uljs reportedabove as statistical I) ignificam Based ontile data virgin and low concentrationcoolants are predicted to initiate corrosionmore quickly than reclaimed and highercoacentration coolants

Heal treat condition alsoaffected theinitiation of corm ion in that rugh carbon(carburizeCl) urface were more resi tanl110 initiation as compared 10 core (unear-burized) wfaces It was also ynthesizedfrom the data set hat u edreclaimedcool ants offered better corrosion resi tanceIhltlll the virgin mix in both synthetic andsoluble oil eoolants The data also suppon-ed using the soluble oil cool ani as the pre-ferred cutling fluid As a result of the

experiment the soluble oil water-basedcoolant was implemented in the gear pro-duction area as part of Phase n work

Based 011 the results of the first DOEthe trntegy fOJ the second experiment wasdeveloped The factors selected for Ihi experiment were ceolant concentration(3 and 6) base material magnetism (0

gall sand 10gauss) pecimen una ~ fin-i h (6 Ra and 36 Ra) iron particlesincoolant (clean coolant and panicles 8i ded)specimen raw material heat lot (heat lots 1and 2) specimen heat treat condition (car-burizedand uncarburized) pecimen alloy

vent condition (virgin and used) and pre-servative oil application (four-minute soakapplication and pray application) At heIlggestion of manufacruringpersonnel the

additional factor that was added tn jhe

DOE was the method of preservative oilappli alion Previou process mappinganalysis revealed that a lypical lot of gearscoald go through the preservauve soakcycle 24 limes If the soak cycle could be

with the arne result significant sBvingsincycle time and cost could be realized

With the factors and level middotettingsestablished the DOE was execUled asdescribed previously However there was

no corrosion initiation observed on tilsamples after six months The experimentindicated that the factors te ted would n t

initiate corm ion provided a c tiIq ofpreservative oil was applied regardle of

THE PURDYCOPORArION

150 9002 CERnFIED

S86 Hilliard Stree~ PO BOJ U198 Manchester CT 06045-1898 USATelephone 860 649-0000 bull Fax 860645middot6293

Home Page httpwwwpurrfytransmissionsromf-Mail salespurdytransmlssonscom

Cll19B TgtI II_~11OII

WW pOWllrnmluUMcom bull g middotchnologycom bull GEAR TECHNOLOGY JUl YAUGUST 2002 39

TECHNOLOGY FOCUS

Attack

I i I

l I I

-i I

middot1 2

2 I

I Lllvel +bull Level bullbullFactors

pHCopper ozJgaLExposure time Iminl

1039990

866345

Figure6-Alkalille Strip ExperimentMatrix

Figure 7-PCI- Win Probe System

Figure 8-PClmiddot Will Sweep Output

application method Based on this resunthe manufacturing specification was modi-fied to only require a quick immersion inlieu of a four-minute soak The practicewas quickly implemented in Phase U

Chemical AttackDuring the project a large quantity of

gears were exhibiting a pitted condition atthe machining operations in various areasAfter metallurgical examination it wasdetermined that the pits were a result ofchemical attackcorrosion Since themachiae cutting fluids cleaning andpreservation factors had been previouslytested in Phase I they were quickly dis-missed as the root cause This allowed theteam to focus the investigation in the plat-

ing facility The key factors were identifiedthrough a thought process mapping exer-cise Possible initiators of the attack werealkaline pHexpos1IIfe time and the ouncesof copper in the alkaline strip solution Anexperiment was designed to test these fac-tors an 9310 steel specimens as shown inFigure 6Analysis of the experiment iden-tified pH as the factor with the highest sig-nificance Data also indicated when the pHlevel was greater than W chemical attackdid not occur

For phase II implementation the teaminstalled a controller on the alkaline striptanks to maintain the tank pH levels abovelO3 by automatically adding anhydrousammonia when the pH level droppedbelow 103 It was noted hat during theanhydrous ammonia addition an exother-mic reaction occurredheating the solutionto temperatures above HJOFThe problemidentified with the elevated temperaturewas that when the alkaline stripping SOJII-

tionreached temperatures above 77degP itbecame corrosive to carbon steels Theteam installed a chilling unit in the strip-ping tanks to stabilize the solution temper-ature at 60E After installing the chiller andmaintaining stable pH levels at 103-107no chemical attack on an entire lot of gearshas occurred due to pH imbalance as a rootcause

bull A corrosion-protective film could beformed after processing through either thecoolam or preservative solution typicallyapplied during the msnufacnmng process

Test results indicated that residua]coolant would leave a short-term COITO-

sian inhibiting film an the gears similarto the ones resulting from immersion illan oil bath This residual film couldreduce the incidence of corrosion even ifthe preservative oil was not applied Ifthe proper fluid attributes could be meas-ured and maintained not only wouldcostly corrosion initiation be greatlyreduced but the corrosion preventionsteps (preservative baths) could also bedecreased or eliminated

On-line PCI-Win ProbeA significant barrier to relying on resid-

ual coolant as rut effective short-term COf-

rosion inhilbitor is determining if thecoolant has he proper attributes Standardcorrosion testing takes too long to giveusable information ill an Oil-going produc-tion environment For example this testingprocedure would take approximately 48hours to complete at added cost for coolantanalysis The teams goal was to find a toolto provide real time sump-site testing topredict the coolants corrosion inhibitingproperties

After further research the team decidedon he use of an adapted Digi-Galv probingsystem PCl-Win Probe similar in operat-ing principle to the one u ed in the oilpipeline monitoring industry The probehasthe potential to provide quick indica-tionsof a coolants corrosion-inhibitingcapabidties

The PCl-Wm Probe system shown inFigure 7 consists of a small test cell (spec-imen housing and electrode) a digitallycontrolled dual range precision instrumentunit and a standard Pentium desktop PCwith the AMPLICON PC30AT crud andassociated software installed In additionthree accessories are added a glass sleevesample vessel a constant temperaturewater bath with tubing to allow flowthrough the glass sleeve and a pump toprovide circulation of the sample Theaccessories create a testing environmentthat simulates the actual conditions under

Residual CoolantEarly in the project it was determined

by extensive laboratory testing that water-based machining coolant was an effectivecorrosion inhibitor Low carbon alloy gearscoated with a film of in-process coolant didnot corrode after two months in the highheat and humidity test chamber

The results of this testing werebull Used coolant is not a corrosion enablerbull The coolant solutions ability to form aprotective film barrier on the surface of thepart determined its ability to inhibit corro-sion Whether this film came (rom virginor in-process coolant was irrelevantbullIf a film was not left on the part by thecoolant after the machining operation andit was not properly treated with a preserva-tive oil then corrosion was enabled Suchcorrosion resulted in increased manufac-turing costs andlead times

middot401 JULYAUGUST 2002 GEAR TECHNOLOGYmiddot wwwgeartechnoQgycom wwwpowertransmss on com

which he coolantsperform in the metal-

working machinesThe PO-Win Probe effectively meas-

ures the electrical resi lance between theprobe and metal specimen while both aresubmerged LI1 the coolant being analyzedThe resi tance represents the film formedby the coolant on the specimen The higherthe resistance the more complete the cov-erage and he thicker he film This resis-tance is measured and graphed by the PCI-Win Probe system in the form of asweep shown in Figure 8 1be sweepconsists of two parts cathodic and anodicThe anodic portion (above the X-axis orpo itive voltage values) of the sweep indi-cates the rust preventative (RP) packagesof the fluid The longer the curve remainsin the vertical upswing the better RP pack-ages in the fluid Also he further to the leftthai he inflection point occurs the betterRP in the fluid In general an inflectionpoint at 01 to the left of 10 lA indicates afluid that is considered to be a goodinhibitor of rust As the RP package weak-ens the sweep tends to trail off toward theright If no inflection point oecursat alland the sweep continues flatly toward theright it demonstrates that the fluids RPproperties have depleted and are providingvery little if any rust proteclion

Using two common gear materials lab-oratory testing of five water-based metal-working coolants and validation testing oftwo coolants were completed Sample test-ing was done at Honeywell Engines andSystems Ten machines were strategicallyselected to provide a broad range ofmachining processes and coolant condi-tions lin total 10 weeks oftests were runwith he two conditions for 9310 alloy andthree weeks of tests were run with the twoconditions for Pyrowear X-53 alloy Thepurpose ofihe test was to validate previousresults and to directly oorrelatethe datagathered in the sweep (location initiationof inhibition) to he daily concentrationpH bacteria and total dissolved solids(TDS) levels

The results obtained in the lab did agreewith the Phase I results In comparing the

TECHNIOLOGY FOCUSbetteroorrosion inhibitor than theChemTool Cf-757 synthetic coolant Notonly did the coolant type make a differencein sweep location and shape the type ofalloy was also a factor For the Pyrowear X-53 alloy the sweeps were shifted far to therigilt In the DOE phase of this projectmetal coupons made of PyrowearX-53 and91310 were placed in a humidity chamberand monitored for the initiation of corte-ion The Pyrowear X-53 coupons exhibit-

ed corrosion initiation before the 9310which correlated to the 1PC1-WinfindingsAdditionally it was dear that routine con-centration pH bacteria and IDS testingdid not predict pertonoance of rust inhibit-ing packages in coolants

The PCI-Win Probe system did showan ability to differentiate between the twofluids corrosion inhibiting pertormance

However in its current form the PCI- Winsystem is best suited for a laboratory envi-

AMI Systems Co announces tllat II Is now amanufacturing source of spiral gear roughingand finishing cutlers and bodies

We also can rnanutaeture new spiralcuner bodies In diameters 01 S through 12at present

AMI can also supply roughingiand finishingcunsrs for moslS-12 dlameler bodies

Whelher its service or manlllaclllring con-sider us as an alternative source for cuttersand bodiesYoull be in for a pleasant surprise

NEW Hob and Sbaler c-uner Resllarpeningis Inow IIvailabh at AW Sifs1ems Companv Royal Oak Michigan 48067

Tel (248) 544middot3852- Fax (248) 544middot3922Pel-Win sweeps it was evident that the

FUCHS PT-97 soluble oil coolant was a SEE US AT IIIMTS 2002-800TH 8-7130wwwpowerrransmssoncom wgearI8chn0ogycom bull GEAR TECHNOLOGY JULYAUGUST 2002 41

ronment Additionally because of severalequipment stability issues the team decid-ed that it was not robust and precise enoughto implement for production floor useMore testing and evaluation were requiredAs further research and development isconducted it is expected that this technolo-gy could become a useful predictive toolfor both lab and production environments

ConclusionsWhen corrosion occurs during the man-

ufacturing of gears production costs asso-ciated with scrapping or rework escalateand product delivery delays are likely dueto the disruption of work now within theproduct lines Based on this project the keyparameters and preventative practices tominimize corrosion during the manufactur-ing of aerospace gears have been identifiedas followsbull Coolant condition type and coolant con-centration are the major factors effectingthe initiation of in-process corrosion In thisproject low concentration and virgincoolants will initiate in-process corrosionmore rapidly than higher concentration and

TECHNOLOGY FOCUS

reclaimed coolantsbull With respect to inhibiting in-process cor-rosion soluble oil coolant performed betterthan synthetic coolantbull Carburized surfaces are more resistant tocorrosion initiation than uncarburized sur-facesbull Corrosion protection results are similarregardless of the preservative oil applica-tion method quick immersion or severalminutes soakbull The alkaline strip step in the platingprocess is a major source of chemicalattack Maintaining pH levels between103-107 and fluid temperature at 6OFmaximum in the alkaline strip tank willminimize the potential for chemical attackon gearsbull Residual coolant can be an effectiveshort-term corrosion inhibitor therebyeliminating the tirne-consuming and costlyoil preservative steps during the manufac-turing of gears The key to implementingthis practice is to have a reliable method ofmonitoring the coolant conditionsbull The PCI- Win Probe system has the

Newage provides more choice in case depth analysis with two powerfulsystems for making traverse case depth analysis Both systems provide a

significant advantages depending on your application

System 1 Auto-CAMS with the Most Capability (SEE ABOVE)System 2 MT90 with the Highest Speed (SEE OUR WEBSITE)

DOWNLOAD PRODUCT liTERATURE FROM OUR WEBSffE AT WWWHARDNESSTESTIERSCIIMI

~ftaTel800-806-3924215-526-2200 Fax 2H-526middot2192 147 James Way Southampton PA18966

potential of characterizing the corrosioninhibitor characteristics of a coolant

Recommendations for Future WorkAdditional work On developing the PO-

Will Probe system as an online coolanttester is recommended Once the coolantscorrosion inhibitor property is ascertainedthrough online testingthe possibility existsto eliminate the preservative oil altogetherand rely solely on the residual coolant as aneffective short-term corrosion inhibitorSuggestions for improvements to the PC]-

Win Probe system include the followingbull The calomel electrode should be manu-factured to a tighter tolerancebull A calibration method must be developedfor the PCI-WilrProbe system to improveaccuracybull The probe assembly should be repack-aged to be mor-e rugged and portable

AcknowledgmentThis project was conducted by

Honeywell Engines amp Systems and admin-istered by lIT Research Institute IlTRfjthrough the INFAC (Instrumented FactoryforGears) Program which is funded by theUS Army Aviation and Missile Command(AMCOM) Process mapping was doneboth at Honeywell Engines amp Systems andBell Helicopter Textron Inc Humiditychamber and coolant testing were conduct-ed at Honeywell Castrol Industrial devel-oped the methodology for the PCl- WilllProbe testing of the coolants The authorswould like to thank the staffs of AMCOMlIT Research Institute Honeywell Enginesamp Systems Bell Helicopter Textron Incand Castrol Industrial for their help andsupport all this project 0

ReferenceINFAC Corrosion of Aerospace GearsINFAC Manufacturing Method Reportnumber 00-001 Chicago February 2000

Tell Us WhIt You nillk Visit wwwcomtubullRIll_Ibull ReqIIIIlIDOf8 iaftnuIion

I bull COIIaCt 1UIIIors 01 COIIIpInili mentionedbull Make 1UIIItItionOr callM7 G1~ 1IIk IDana m 1IIiIDrI

42 JULYAUGUST 2002 GEAR TECHNOLOGY wwwgearlechnologycom wwwQowerlransmiSSioncom

I

I

The Broach Masters tne IUniversal Gear Company Gear amp Spline IBroaches bull Shank amp Disk Shaper Cutters Special Form Broaches bull Generated IForm wilth ground IFiUetRadiuseNe Gear Grinding- Go NoGo Spline Plug Gages Production Broachingl- Posi-Loc Spline Arbors Blind Hol~eBroaching Specialists- Master Gears

(5310) 885-t 939 Fax (530) 885~B 157 (530) B85~5o751605 Industrial Drive Auourn CA 95603 Made in USA

wwwbroachmasterscom salesbroachmasterscom

t- iPRODUCTNEWS _

Products for the Gear Industry

INew Polvmer for Brake Ac1uatorFrom Victrex USA

TIlePeektrade polymer was chosen as thematerial for the actuator unit of an elec-tronically controlled parking brake becauseit allowed TRW of Koblenz Germany todevelop a high efficiency gearing conceptwith a transmission ratio of 50] within alimited space

According to Victrexs press releasethe polymer provided lighter quieter run-ning parts than could be achieved withmetal

On this gear as embly high torque wasto be transmitted in a chemically aggressiveenvironment within a limited space Thesubassembly sits 011 the caliper in the rim aresult of which was that the constructionspace available for the gearing was only208 in diameter and 12 in height

Victrex USA is a manufacturer of highperformance polyketones

For more information contact Victrex USA Inc of Greenville SC by telephone jat (864) 672-7335 or on the Internet at IWWl1lvictreXCGrlL j

New Gearml from Dow ComingMolykote synthetic gear oils from

Dow Corning Corp can las three timeslonger than conventional mineral oilswhile reducing power consumption by asmuch as 17 in worm gearboxes accord-

ing to Dow ComingIn its pre release the company said

the oils longer life is po sible due to pro-prietary anti-oxidant additives and a man-ufacturing proce s that eliminate impuri-ties which lead 10 oil degradation

The e gear oils are designed for use inworm helical spur bevel hypoid andrack and pinion applications and meetmost equipment OEM lubrication require-ments

For more information contact DowCorning of Midland MI by telephone at(800) 637-5377 or on the Internet atwwwmolykotecom

Flaw iDe1ec1orsfrom Agfa NOTThe USM 25 Serle of portable flaw

detector from Agfa NDT weigh 35 lbsand has a range of 0020 in steel foroptimum thin-range u e

According 10 the companys pressrelease curvature correction has beenadded to compensate for trigonometricflaw location calculations when perform-ing angle beam inspection on piping andtubular goods Two independent monitorgate along with automatic A-Scanfreeze for both gates provides versatilityand simplifies thickness measurements

Multiple-curve DAC with twocurves above and below the originalrecorded DAC curve enhances criticalflaw sizing capabilities An alphanu-meric data logger option provides stor-age for 5000 thickness readings andthe ability to attach 500 A-Scans to

thickness readingsFor more information contact Agfa

NDT of Lewistown PA by telephoneat (717) 242-0327 or bye-mail atinolinkagfandrillccom

New Gear Factory Software fromIChrisWatts IDesign

Chris Walts Design is offering a newsoftware system for AutoCAD 200020001 2002 and MDT u ers The soft-ware called Gear Factory includes adialog box that allows users to createstandard or custom 3-D solid models 2-D entities or 2-D isometric entities ofstandard involute gears

According to the companys websiteusers can specify the pitch pressureangle number of teeth width and inser-tion point of gears The soflware is avail-able for $7995 per unit

For more inforraation contact ChrisWatts Design of Ojai CA by telephoneat (80S) 649-8038 or on the Internet atwwwcwattsdesigncom

INew Slizesfor Gearheadl Serlieshom Thomson Industries

Thomson Micron LLc added 90and US mm sizes of planetary gear-heads Available in both in-line and rightangle models these gearheads are suit-able for applications like material han-dling packaging coil winding pipe

44 JULYAUGUST 2002 GEAR TECHNOLOGYmiddot wwwgurrechnofogycom wwwpoworransmissioncom

RevI

II tionvol

FullvIUBtull capacityrightwher you ne_ d it

Automatic gear spline worm and wormgear inspection

bull Compact portable andl shop-hardened

bull ReliaJble four-a_xjs accuracy bull Ideal for manufacturing cellsbull IProven Wlndows~ based MampM software

Ii fEI18111N rEMBIIIIObullbull IIN

gma

ThB ultimate inliln-pection performancebull 31Dprobe with quick-change probe assembliybull Linear motor direct drives for higher speedbull Four-axis generative motion for optimum accuracybull Windowsreg based software - ideai for all types of

gears and gear cuHing tools

ILearn how the Micro-top and Sigma Series systemsmeet your requirements Call 937859-8273 or visitwwwmmprecision com

Vlisit IUS a IMiTSst Booth B7132

New Generationof CNC Grinders

The Parker Majestic Division of PennUnited Technology announced the devel-opment of a new generation of CNCcylindrical rotary and profile shiftgrinders

The Liberty Series are Siemens 810-powered machines with a 12 x 10 or a 14

46 JULYAUGUST 2002 bull GEAA TECHNOLOGY w wgesrrechnclogycom bull wwpowefsnsmuloncom

WANTEDMORE ACCURACY

MORE EXPANSION

MORE VERSATILITY

LONGER LIFE

AND LESS COST

THE ANSWER FOR 150 VEARS

LeCOUNIT Inc12 Dswiu Dr bull PO Box 950 Whits River Jet VT 105001 USA

lei (OOtlll642-amp-713 or 1(8021296-2200middot Fax (802)2966843 E-mail lecounlsDvernatWebsite hUpiwwwlecount com(includes pn)dlJct specifications)

__ PRODUCmiddotT NEWS _

bending machine tools overhead gantrysystems and injection melding machines

With a standard four ar middotminute back-lash and crowned helical carburized steelgears that are hardened to HRC 60 mini-mum and flank-fin] hed after heat treat-ing the gearhead are made to operatequietly According 10 Them on pressrelease the gearheads strength and tor-sional rigidity result from machiningboth the Output housing and the helicalinternal gear from a single piece Of hightrength steel

For more information contactThomson Industrie Inc of PortWashington NY by telephone al (516)883-8000 or by fax at (516) 883-9039

New Helica~Shaft Mount ReducerEmerson Power Transmission intro-

duced a newly redesigned Browning hel-ical shaft mount reducer

The new haft mount line incorpo-rate a ingjetapered bushing mountingsystem and a barrier steel system

The single tapered bushing mountingsystem is reversible and allows the bush-ing to mount from either side Wt includesa tapered stabilizer ring that minimizeswobble and resists fretting corrosionAccording to EPTs press release thisy tern reduces shaft binding found in

two-bushing systems and can replaceany competitive single- or double-bush-ing shaft mounts

The barrier seal system combines a v-ring face eal grea e-fitled labyrinth androtating outer flnger to provide tripleprotection against contamination and oilseal damage

For more information contactEmerson Power Transmission of JlbacaNY by telephone at (606) 564-2084 Oronline at wwwemerson-eptcom

PRDiDUCT INIEWSI _--- ------

x 30 capacity De igned to simplifylilemanagement and programming the seriescan be configured as an m 00 or comb i-nationgrinder Additionally it features a 5hp 00 motor and [5 hp ID motor

The Revolution Serie contains CNCrotary grinders with II 14 maximumdiameter capacity chuck These grinderscan be configured with 3 vertical or hor-izontal grinding spindle and are switch-able from aile to the other Grmdershave the capacity to grind ring andspacers flat within 00000 1 and aremenu driven

The Freedom Series of CNC profileurface grinders is comprised of 3-axls

Siemens 810- and 840D-poweredmachine with an 8 x 18 table capacityand an optional C C over-the-wheelform dire er These grinders can also beconfigured with a CNC rotating orindexing fixture

For more information contact PennUnited Technology of Saxonburg PA bytelephone at (866) 572-7537 or on theInternet at wwwparkermajestic com

ing tower applications by adjustinglbeheight ofjhe output Shaft Also the locationof the change gears was designed 0 thatspiral bevel gears within the rnain housingdo not have to be modified 10 cbange ratios

Numerous gear ratios call be achievedby using different sets of change gearsextemalto the main housing Thereforethe company says the drive can beinstalled ill 24 hours with only the small-er change gears needing to be installedwhen the unit is ordered

For more information contactPhiladelphia Gear Corp of Nord townPA by telephone al (800) 766-5120 or onthe Internet at wwwphilagearcol1l

Ten Us Whit You Think VlIit www~clDbull RIa this col_bull Request lIIOI1 infannatioabull Contact camplnilllllllltionetlbull Mak IlIItIgutionOr CIIIIM7l437-4IIIM1DdID _ 1

Call NowOur experienced engineeringteam is ready to assist you ingear d sign or problem soJving

for gear design andmanufacturing

Technologicallyadvanced machinery ReishauerRZ362Nilmiddot s Kapp ZP08ZP12and many others

bull Competitive prices

bull Fast deHvery

bull High quaUty

bull Responsive

bull Highly I xperienced

New UniversalCooling TowerDriivefrom Philadelphia IGearA new universal cooling rower drive

from Philadelphia Gear Corp is de-igned to replace cooling tower drives

and pare partsAvailable in two sires he universal cool-

ing tower drive can be used instead of otherdrive model bull with minimal modiJication Itcontains spacer plates and change gears

According to the companys pre srelease base plate spaee adapters make thedrive modifiable to most other legacy cool-

IIfWWpowertransmSSloncom bull www geartachnologycom bull GEAR TECHNOLOGY JULYAUGUST 2002 47

FAIRFIELDGEARED FOR EXCEHfNCEIFairfield Manllfactlll1ing Company IincLafayette IN 47903-7940 USATelephone (765) 772middot4000FAX (765) 772-4001IIIWWfairfleldmfgcom

----~-

~ - SEE US AT IMTS BOOTHI 18-6781 ~ I

~~~ The D C ~ Company~ 201 Johnson Street- POBox586 Covington KY 41011

1 ~QY Ph 859-581-7511middot Fax 8595819642middot wwwdcmorrisoncomI~~O I E-mailrvbbJjunocom

I uTHE KEYSEATER SmiddotPECIALISTSnNEWI lts fully

VARIIIAiBLE$PEED Automatic

TOLL FREE888-246-6365

NUMERICAl CONIIROllEOIHEAVYDUTY111J4-Inch

KEYSEA TER

bull QuickmiddotSoI upbullAulomalie feedbull AYIomIilliltOpbull Cub Keyways 111110 1N

Special Feaures tncudsbull Infinite speed and heighladjijstmentbull Cuts up to 3middot wide and 14 longAutQmatic lube with alarmIneil 01 Metric capabiIitiesbull all proof data entry boardbull Digital Read-OutChip remosal chute

All at a bargain Iprice

THE KEYSEATERS WITH MACHINE TOOL ACCURACY

bull Our visitors are your buyersbull We deliver over 130000

page views a monthbull For only $995 per year

48 JULYAUGUST 2002 GEAR TECHNOLOGY wwwgeartechnotogycommiddot wwwpowertransmlssloncom

- - -

ADVERTISIER INDEX--- -

SU America IncUnited Tool SupplyVOl Veri

USE RAPID IREADERIRESPONSEto centaet any advertiser in this issuewwwgeartechnologycomrrrhtm

Rapid Reader RespDnse Its FAST Its EASY Its ONLY ONUNE

Ajax Magnethcrmic CorpAmerican MeLal Trt~ating CoArroraquo Gear CoAIW ysrems CoBaril International CorpBourn amp Koch Machine Tool CoThe Broach Masters loclUniversal Gear Co

Chamfermatic IncColonial Tool Group IncThe DC Morrison Co

Dr Kaiser (SL Munson)Dragon Precision Tool Co LId(Greg Allen Co)Dura-Bar

Fairfield Manufacturing Co IncFis~ler orp

Gear MOlions IncG~ar Tec~nology ~Center 01v of MII~ubl hi International CorpGleason CorpGleagton CUlling Tooh CorpThe Gleason Work~rMTS 2002

Index Teehnologie Inc

I

Insco Corplater tal Tool Corprrw HeartlandKlingelnberg-OerlikonKoepfer America lLcKreiter GearteehLeCoumlnc

Liebherr Gear Technolo y CoLMTmiddotFetteMampM Precision Systems Corp

idyel Gear amp ioollncMidWe51 Gear CorpNewage Te~Ling Instruments Inc

Niagara Gear Corp

PcIt Technology Corppo enrunsmissioncom 1loI

The Purdy CorpReishauer CorpRussell Holbrook amp Henderson IncSun-SU IncStar-S Inc (Wesl Branch Indu tries)

4715

50

1350

15051lFC14

511651178

515146

Pagel

1631

50514

41461743

191048

3332

5

356

45345142

5051

IBC4839II4

BC51

315Jt

Pholl

(703) 684-02 II

(800) 547-1527( 16) 431-4191(630) 969-7640(248) 544-3852(smiddotm 272-8128(815) 965-4013(530) 885middot1939

(815 636-5082(519153-2461(888) 246-6]65(859) 581-7511(800) 775middot1390(440) 331-0038

(800) 22706455(815) 338-7800(765) 772-4000(414) 769-0072

(315) 488-0100

(248) 669-6136(585) 473middot1000(8151 877-8900(585) 173-1000(800) 3224687(703) 893-2900(440) 895-t627r978) 448-6368(216) 671-1077(320) 762middot8782(734) 429-7225(1147) 93141111713) 237-9793

(800) 642middot6713( 02) 296-2200(734) 429-7225(734) 0129-2095(937) 859-827(586) i)lmiddot89~J(330) 425-W19(800) 806middot3924(215) 526-2200(800) 447-2392(7161874middot3131( oo) 738-2525(8-17) 437-6604(8OO)649-0000(847) 8 -3828(20 I) 796-5445(847) 649-1450(888) 73742771(989) 34 -2865

(847) 649-1450(800) 755-0516

(49) 2lIfiJ8ampmiddot133

Ep[ail

lechagmaorggearcxPoagmaorgajaxsales ajaxmagcQmmark(pound1 arncricanmetaltreatlngcembevel~ijrruwgellcom

peoplebaritcomboumkochworillnelaunetsalesbroachmasterscom

chamfeaolcombmfroal mninelrvbbjjUl1ucom

infoslmunsoncomgallencomsncom

salesdurllmiddotbarcom

sales fairficldmfgcomusufaeler-agch

info mitsubi shigearcenter comdmelton iilgleasoncomdmcllOnglcasoncomdmetlon leasoncom

Intlm t

wwwagmuorg

wwwajoxmagcomwwwamericanmetaltreatingcomwwwlITOwgcarcnm

wwwharilcomwwwbourn-kochcornwwwbreachmasterscem

po rrrIlmluIOIlcom gesmiddotIchllologycom bull GEAR TECHNOLOGY JULYAUGUST 2002 49

gaJlenCQ ~comsalesin~cocorpcom

itwgellnitwgearscomklaussin ler1 tliebberreorn~a1elkoepferameric~comkreilerkreiler- eaneeheomIcoounl over net

info gllicbherrcomlmlfeltellmlfetccominfQmmpreciiUl~Qmroscrnltillobalneronhmw earcominfonewagein trumentscom

infoniugaragearcom

sale~(glpcrr)gearcomptsalcllltlwe11mnmissioncomsalespurdytronsmissionscomreishauerjarelshauer-uscomsaleststru-voluteccmsWeSMl- ucornsales~U1r-sucom

alessuamericacomunitedteoll ao]colTIpkoethcrvdi-nachrichlcncom

wwwcoloniltoolcomwwwdcrnorrisoncom

wwwgnllencccomwwwant roncokrwwwdurnmiddotbarcom

WIIIwJairfi hlmfgcomwwwfue ler-agch

wwwgcarmoricnseem

www rnitsubi higearcentercomwwwglcasoncomwwwgJcaloncomwwwgleasoncomwwwirmsnetorg

wwwinscocorpcomiiwintcrstalctoolcorcomwwwitwgearsecmwwwklinaelnbes cemWvJoepferamericacomwwwkreiler- eaneehcemwwwlecouncom

wwwlicbherrcQrnwwwlmtfenecornwwwmmpreciioncom

WIIWmw eaacomwwwhardnesstesterscom

wwwnlagurugeurcom

wwwperrygearcomwwwpowenransm issioncomwwwpurdylmnsmi~ionscomwwwreishauercomwwwtru-voluiccornwwwstur-sucom

w-WWslar- ucom

wwwsuamencaccmwwwcnite-a-rnariccomWWVI vd i-literuturde

--

CLASSIFIEDS- -

----

WEBSJTES

GLEASON CORPORATION(k~ltIIIlhl ~Jhl 111l11~IIIPldhmiddotlblV

nlllIll 1) ~l11 11I~IIIIILldIIIII~ hltllll)II)

~~ Vl olltr d ltlillprLllllhll ~tlr l1I11111~

IIIiIllilh pn~~f11l1Itll 111 ~)lmiddot~tI Ilthhill~111111111 lid ~lIlIdl~ppllloIl1 III Idllc1 I h1 ~cmiddotIlil lcun d~11I1

(lUI Idmh 1 lIfcc (I 11111 ~lOIl(ll1 illluHlIlti(JlI lmiddotmiddot 0111 dl illmiddot

wwwgleasoncom

wwwniagaragearcom

--

IJTERATURE

I HELP NANTED

Nationwide distributors and salesper-sons with gearing knowledge neededStrictly on comrmssiens onliyEuropean-made gear cutting grinding

land inspection machines Write toNEYDEKLlCAOLCOM11- -11

TO ADVERTISE IN THECLASSIRED SECTION OF

GEAR TECHNOLOGY MAGAZINECALL PAT FLAM

AT (841) 431-6604 TODAYI

Rates---Line Classified 1 minimum $325 Additional lines $45 per line (8 lines per inch) Display Classified 3 minimum lX-$735

JX-$68S per insertion 6X-$645 per insertion Additional per inch lX-$2-5S 3X-$23S per insertion6X-$225 per insertion Color~ Add $150 per insertion for color Gear Technology wiU set type toadvertiser 13)001 or design a classified ad at no extra chargePoymet1t Full payment must accompany classified ads Send check drawn in US funds on a Usban_k or VIsalMaltterCJIdAmericruIExpresnumber and expiration date 10 Gear TeclUlology PO Box 1426 Elk Grove VillageIl 60009 Agency Commission No agency commission onclassified ads Materials Deadline Ads must be received by the 15th of he month two months prior 10 publication Acceptance Publisherreserves the right to accept or reject advertisements at his discretion

50 JULYAUGUST 2002 GEAR TECHNOLOGY WWWgtJlulschnologycom bull wwwpowsrrrBnsmssioncom

--- ----

SERVICE----_

HIDlb SharpeningServiee

west ~ IndustriesA Subsldiary of Star Cutter CompanV

2083W 1M-55WestBrilncb MI4866111-8I1I1-Reshml1-8e87374277

Tel (989)345-2865 - Fax (989)345~6a

Illnduction HardeningSpecialists in TDoth bV loothlContour Hardeningllof InlernslSputhelical and bevel gearsOur gealr hardening equipmelltincludes S NAlCO submergedprocess machines and 5 AJAXCNC-controlled glear scanningmachines Tooth by tooth gearhardeningl from 50P-10DP up to15 tons 200 diameter

American IMe1al1ireatIng ICompanyClenland IOhio

Phone 121614l1middot4492~ Fu (2161431middot1508Web wwwlIlI1sriclUlmsf1lltrf1lllingcom

E-mail mdBmericBnmll11dtreatingcom

IBreakdownl Service Avaifablel

IHOIB SHARPENINIGINDEX TEICHNOLOGIIES

t c 11 AGMA - ~l~ Cla~s tAIllndexo = Helical

010 bull Skiving 9 bull Carbide

-up to 125 NDP capacity-recnatinq amp stripping of allcoating types

-rapid turnaroundIndex Technologies lne

211135 Lorsin IRo dFaiNiew Park Ohio 44126i

Pllone 44O-896-462JIIHOBS)Fax 44ij331-0516i

Email Igallencomsncom

WIIbull pOWmiddotsmluoncommiddot www rfennotlaquo com bull GEAR TECHNOLOGY JULYAUGUST 2002 51

Gleason Cutting ToolsCOR PO R AT I 0 11

1351 W1Idsor RoadLoves Partlt IlL 6111111USA

IPhone 8115-877middot8900Fax 815-877middot0264

Website wwwgleasoncomIEmiddotMail gctcgleason_com

bull State-of-the-art CNCsharpeningand inspection machines

bull Wet grinding with free-cutting CBN ordiamond wheels tor Burn freeN sharp-ening of carbide or high speed steel

bull Optional recoating and strippingl

bull Rush service available

Koepfer America LLCI63S Schneider DriveSouth Elgin IL 60177Phone 847-931-4121Fax 847-931-4192

leskoepferamericacom

GEARTOOTHGRIINIDIINIG 8ERVIICESSpur bullHelical - Double Helical

Capacity up to 605 DO 1 DiI~291 I

Stroke All ground gears certified up toAGMA Class 14+ on Zeiss-Hofler 16U2CMM Inventory of grinders includesHofler 800 Hofler 1253 Supra Hofler 1500two Hofler Nova CNC l000s (Fully GNCWith on-board CMM checkerl andHofler IRapid HIOO Form Grinder

Kreiter Geanech2530 Garrow St Houston rx 77003Phone 713middot237-9793 Fax 7113237112091

Contact Mr Willie WhittingtonVisit our Website atwwwkreiterg98itechcom

wwwnterstl bullbull toDlcorcomTal 216-6111-1071 bull fax 216-611-5431

CUSTOM ENGINEERED ampMANUFACTURED CUTTING TOOtS

ESTABLISHED 1960

FORMI REUEVED amp PROFILE GROIINDMIWNG CUTTERS

GEAR SHAPER amp SHAVING CUmASALL CLASSES OF HUBS

HSS SOUD CARBIDE amp CARBIDE TIPPED

WHETHER YOU NEED NEW TOOLSMODIFICATIONS RESHARPENINGREPAIRS OR MampM INSPECTIONS

CONTACT liS FOR A QUOTE TODAV

-

PREC~SION GROUND GEARSI Spur HelICal and Pump

Gears 10 AGMA Glass 15bull Featuring the latasl grinding

and eNG 1echno1ogy includingbull Relsl1auer Al300E Electronic

Gear Gnndersbull Gleason TAG 400 CNC a-axis

High ProductionGear Grinderbull Full CNC Multi-axis Cylindrical

Grinding (Internal and External)bull High Performanoe CNC Hobbing

bull Continuous Process ImprovementUtilizing SPC and Quality Planning

bull JIT Delivery using InnovativeSiocklng Programs

800-447middot2392IFax 716-874-9003wwwnlagaragearcom emalllnfotnaglrage_com

GEAR TOOTH IGRJNDINGSpur bull Helical

bull Herringbone Iwith groove)Capacity up to 63 OD

1IDP 16ac8

AGMACertjfication InspectionDelivery to Meet VourHe uiJlemenu

Miidwest Gear CoriP2182 IEAurora Rd

Twinsburg OH 44081Phone 330~425~441191

Fall 330425-8600

Direct your inquiriiestalIRonHumprueVGeneral Manager

ronhmwQoarcom

ADDiENDUiMI

-- - - --- -- ----------

me ar n~anufacturer bull typically u eplastic steel or other metals 10

make their gears but AndrewShotts made his fir 1 gears aut

of sugar and chocolate

These materials are more familiar 10

Shotts A a pastry chef he has workedin the kitchen of the Russian Tea

Room La Cote Ba que and the oceanliner Queen Elizabeth 2 III 2001 heworked with twa colleagues to create

sugar and chocolate geaJs in that yearsNational Pastry Team Championship

Considered the premier event of thepastry world the annual pastry champi-

on hip requires contestants to create a

chocolate showpiece a sugar show-piece cakes plated desserts frozen

dessert and pelit fours urroundiag atheme Intemational feam vie for agrand prize of 50000

While rackjng their brains for 8

vision of how to best illustrate the 2001competitions Hollywood theme Ihechefs an Team Shotts were inspired by1930s actor Charlie Chaplin and decid-ed to design an entry to honor his per-

formance in Ihe movie Modem TImesNothing symbolized the message of

Modem Times better than a gear saysShotts

II had to be a gear because during

(the) Depression there was so much

more an emphasi on the mechanicalrather than On humans he say

Shotts and hi colleague Patrice

Caillot and Remy Fiinfrock construct-ed two gears One gear was theteamssugar howpiece the other was itchocolate showpiece

We were depicting an old movie reelwith tile sugar howplece say ShottsII the same ize film 16 mm that was

1I ed when the movie was shot The whiteparts are upposed Ie be film wheels andthe entire (annal of lhal gear is represen-tative of that old over-and-under formatof he 1936 movie camera

aThe chocolate showpiece looks

much like the ugar one but there are

some subtle differences between themAt the bottom of the chocolate how-piece for example are fanlike cutoutresembling a shutter Both creationsshow gear curving on either side toillustrate the mechanical nature of fac-tory work during the Depression

Since the creators were trained inculinary arts rather than in manufactur-ing their planning for the contest was

extensive They spent three months

learning about machinery designing atemplate and mixing the ingredients

Shotts Fiinfrock and Caillol began theircreative process at the library research-

ing gears in periodicals and trade jour-

nalsOnce they became comfortable with

the construction of a gear they tried todevise the howpieces out of cardboard

They aved the cardboard template to adisk and sent it to an engineer in

Atlanta who then cut a mold to tbeexact specifications Once they had this

mold back from the engineer they wereable 10 pour the chocolate into it

Each showpiece took eight hours tobake

This year Shotts and his partners are100 bu y with their day jobs to partici-

pate in the National Pastry TeamChampionship 2002 Contest ShOHSworks in ew York as a corporate pas-try chef for Guiuard Chocolate CD andlaunches a new line of seasonal bon-bons every three months

Caillot works as executive pastrychef at New Yorks St Regis Hotel pe-cializing in desserts and Funfrock

explores new desserts in his role asexecutive pastry chef at Cafe Boulud inNew York

Though their gears were probablybetter ta ting than tho e made in facto-rie the creators opted to throw out theshowpieces afterthe compctitionO

Villtlill cinlma Inlpired h creation ot III Igllrwhich il meant ID flprliint th impaRl nee ofmlehinlFl in 18301 Americ- Illor Tbll aUf Iii remiilelat at IIIrs ggd in In anlique Ovl CamplMrIwithl UI_111m

TII MIt You ThiH VIIiI (cct llDld gil

OrCII _al_1IIIDsI52 JUl YAUGUST 2002 bull GEAR TECHNOLOGY wgurechflology com wWwpowlrlrlflsmlsslollcmiddotQm

e can ~ a our ~e8nQa~Q tJQtoAo~Q~afdadand nonsandid cu~nA iDOls

1eaTS()~ellerence manutacunA 8C~ paris complete~~n~me ampotead-mes on oo~pe and cusiom jobs

t)Olens o~ lTocessn~ seQwHnn drvna dsianoa~uo oaned c~cogtgtnampand unna upment~~c~eaTand sptQ sa~na up 44 dameter

CtlC u1namp Ul 0 3011 dame 2011 ona~oll-axis mnampup 0 38 88n lonaiXleM ~ear Bnd s)ne en~neenn~ staff

Mana a~rcan OpoundM Quay approvalsoe1 CMC ~eQ nspecion AOllinlTAht

exttenenced

fry rechnology CorporatloPOBox 2 ~ 29 Industria] Park Road

New Hartford CT 06057Phone (860)1738-2525

Fax~(860) 738-2455E-mail sltdesperrygearWcbsifc COIl

~ Star-SU lnc5200 Prairie Slone Parkway Suite 100Hoffman Estates Il60192Tel 847 649-1450Fax 847 649-0112E-mail salesstar-sucom

fiii Star-SU Inc23461 Industrial ParK DriveFarmington Hills Mil 48335-2855Tel 248474-8200Fax 248 474-9518httpwwwstar-sucom

Together with a complete line of cuttingtools including shapinq cutters and anunmatched service and sales networkthroughout the US the combinedresources of our companies willhe~lp youshape the future ot your business -efficiently and successfullyOur newheadquarters for gear cutting tooltechnology in Hoffman EstatesChicagoprovides you with a comprehensive lineafmachines and tools for your gearmanufacturing needs

Contact us todayto get in shape for tomorrow

e can ~ a our ~e8nQa~Q tJQtoAo~Q~afdadand nonsandid cu~nA iDOls

1eaTS()~ellerence manutacunA 8C~ paris complete~~n~me ampotead-mes on oo~pe and cusiom jobs

t)Olens o~ lTocessn~ seQwHnn drvna dsianoa~uo oaned c~cogtgtnampand unna upment~~c~eaTand sptQ sa~na up 44 dameter

CtlC u1namp Ul 0 3011 dame 2011 ona~oll-axis mnampup 0 38 88n lonaiXleM ~ear Bnd s)ne en~neenn~ staff

Mana a~rcan OpoundM Quay approvalsoe1 CMC ~eQ nspecion AOllinlTAht

exttenenced

fry rechnology CorporatloPOBox 2 ~ 29 Industria] Park Road

New Hartford CT 06057Phone (860)1738-2525

Fax~(860) 738-2455E-mail sltdesperrygearWcbsifc COIl

~ Star-SU lnc5200 Prairie Slone Parkway Suite 100Hoffman Estates Il60192Tel 847 649-1450Fax 847 649-0112E-mail salesstar-sucom

fiii Star-SU Inc23461 Industrial ParK DriveFarmington Hills Mil 48335-2855Tel 248474-8200Fax 248 474-9518httpwwwstar-sucom

Together with a complete line of cuttingtools including shapinq cutters and anunmatched service and sales networkthroughout the US the combinedresources of our companies willhe~lp youshape the future ot your business -efficiently and successfullyOur newheadquarters for gear cutting tooltechnology in Hoffman EstatesChicagoprovides you with a comprehensive lineafmachines and tools for your gearmanufacturing needs

Contact us todayto get in shape for tomorrow

~ Star-SU lnc5200 Prairie Slone Parkway Suite 100Hoffman Estates Il60192Tel 847 649-1450Fax 847 649-0112E-mail salesstar-sucom

fiii Star-SU Inc23461 Industrial ParK DriveFarmington Hills Mil 48335-2855Tel 248474-8200Fax 248 474-9518httpwwwstar-sucom

Together with a complete line of cuttingtools including shapinq cutters and anunmatched service and sales networkthroughout the US the combinedresources of our companies willhe~lp youshape the future ot your business -efficiently and successfullyOur newheadquarters for gear cutting tooltechnology in Hoffman EstatesChicagoprovides you with a comprehensive lineafmachines and tools for your gearmanufacturing needs

Contact us todayto get in shape for tomorrow