GEAR SOLUTIONS MAGAZINE

AN EXAMINATION OF HIGH-CONFORMAL GEARING

An Examination of
High-Conformal Gearing
ISSUE FOCUS
Gear Inspection
Gear Design

COMPANY PROFILE
TRUMPF GmbH Co. KG
FEBRUARY 2018

FEBRUARY 2018
Your Resource for Machines, Services, and Tooling for the Gear Industry gearsolutions.com

GS February 2018.indb 1 1/23/18 12:17 PM

 Achieving Increased Profits and Response Times
with Modular Vacuum, Atmosphere Furnaces

“Initially, what appealed to us about this Ipsen

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

Customer Story

www.IpsenUSA.com Discover this customer’s winning outcome:

go.IpsenUSA.com/Customer-Stories

IpsenUSA.com

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

www.toolink-eng.com

303-776-6212

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 Light Years
Ahead

New 300GMSL is revolutionizing

gear metrology, with full-flank
laser scanning to speed new gear
development. The 300GMSP puts
lab-level inspection on the shop
floor with full networking capability,
saving valuable part transport and
queue time while improving quality
and productivity.

www.gleason.com/laser

© Gleason Corporation. All rights reserved.

2 gearsolutions.com

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 FEATURES

26
TRUMPF GmbH Co. KG
By Kenneth Carter
TRUMPF may have started as a machine tool company,
but laser manufacturing has made it a shining industrial star.

An Examination of High-Conformal Gearing

30 By Stephen P. Radzevich
A look at the differences between Novikov gearing and Wildhaber gearing, making a case for why
the two systems should not be combined as “W-N gearing.”

Induction Gear Hardening

40 By Dr. Valery Rudnev
The practice and science of modern induction heat-treating has advanced in many areas over
the last decade, including computer modeling, power supplies, failure analysis, quality assurance,
and more.

Choosing a Planetary Gearhead

46 By CGI Inc. staff
Motion projects featuring planetary gearheads excel in the areas of system response, inertia
matching, speed matching, system stiffness, and system resolution.

FEBRUARY 2018 3

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 Manufacturers of:

and Universal Gear Company

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

4 gearsolutions.com

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 DEPARTMENTS
08 INDUSTRY
NEWS
Reports, data, and developments to keep
you aware of what’s happening with your
colleagues in the gear-manufacturing
industry around the country and world.
New year, new services added to Solar Turbo Lab’s Turbomachinery & Pump
Atmospheres of Western PA Symposia sees another record year

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

20 MATERIALS 49 PRODUCT 56 Q&A

MATTER SHOWCASE
Mike Helm
Mike Burnett
MANUFACTURING ENGINEERING
CONTROLLING DISTORTION BY CHOOSING
MANAGER
THE RIGHT MATERIALS
Oerlikon Fairfield
Distortion effects can have a major impact on
manufacturing costs and overall gear quality. One way
to mitigate distortion involves in-depth material knowledge.

22 TOOTH
TIPS
Brian Dengel
WHAT ARE YOU MADE OF?
Different materials make gears suitable for the desired
application. The key involves identifying the right recipe.
Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway,
Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year.
Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER:
Send address changes to Gear Solutions magazine, P.O. Box 1210, Pelham, AL 35124. Publications mail

24 SEAT
HOT
agreement No. 41395015 return undeliverable Canadian addresses to P.O. Box 503 RPO West Beaver Creek,
Richmond Hill, ON L4B4R6. Copyright®© 2006 by Media Solutions, Inc. All rights reserved.

No part of this publication may be reproduced or transmitted in any form or by any means, electronic
or mechanical, including photocopy, recording, or any information storage-and-retrieval system without
D. Scott MacKenzie permission in writing from the publisher. The views expressed by those not on the staff on Gear Solutions
OIL QUENCHANTS – UNDERSTANDING THE CHEMISTRY magazine, or who are not specifically employed by Media Solutions, Inc., are purely their own. All “Industry
News” material has either been submitted by the subject company or pulled directly from their corporate web
(PART II) site, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted
This installment explores the chemistry of base oils, to editor@gearsolutions.com.
particularly as they affect quenching performance, to be
followed in March by a discussion of quench oil oxidation.

FEBRUARY 2018
surface of a part.

VOLUME 16 / NO. 2
FEBRUARY 2018 5

3.TOC-2018-02.indd 5 1/23/18 12:34 PM

 EDITOR'S
LETTER David C. Cooper
PUBLISHER

Chad Morrison
ASSOCIATE PUBLISHER

EDITORIAL
Kenneth Carter
Survey lets us know what you’re reading EDITOR

Russ Willcutt
We always want to make sure we are giving you the best and most relevant information CONTRIBUTING EDITOR
about the gear-manufacturing industry as we can. To better aid us in that endeavor, we
recently sent out a survey to our readers to get valuable input on who you are and what you
Jennifer Jacobson
ASSOCIATE EDITOR
hope to get out of each issue.
We received a lot of responses from the survey, and I was happy to see that a majority of
our readers find the articles we publish to be very reliable. Many of you also are gaining a SALES
lot of knowledge from our technical articles and columns and like to share what you learn Chad Morrison
with your colleagues. ASSOCIATE PUBLISHER
We wanted to know what subjects you are interested in, and we will use that information
to better craft our monthly focus topics as the year goes on.
Dave Gomez
REGIONAL SALES MANAGER
Some topics that interested a lot of you were gear design and inspection, and that’s exactly
what we tackle in this month’s issue.
Regular contributor Stephen Radzevich shares his insights on high conformal gearing, CIRCULATION
taking a look at the concept of “Novikov Gearing.” Teresa Cooper
And part one of a series from Valery Rudnev focuses on the “tooth-by-tooth” induction MANAGER
hardening of large gears. Part two will publish in March.
Finally, a quick and informative read from the staff of CGI Motion gives tips on how to Jamie Willett
ASSISTANT
choose a planetary gearhead.
In our company profile, TRUMPF’s general manager and head of its Laser Technology Cole Morrison
division talks about how the company’s laser developments created many advantages in the ASSISTANT
world of gear manufacturing.
You’ll also find some useful information in our standing columns running the gamut
from understanding the chemistry of oil quenchants to how different materials make gears
ART
suitable for a particular application. Rick Frennea
CREATIVE DIRECTOR
I hope you find this month’s issue educational and continue to see more and more useful
information throughout the year. Michele Hall
As always, thanks for reading! GRAPHIC DESIGNER

CONTRIBUTING
WRITERS
STEPHEN P. RADZEVICH
DR. VALERY RUDNEV
D. SCOTT MACKENZIE
MIKE BURNETT
Kenneth Carter BRIAN DENGEL
LEAHLogoLEWIS
Editor Vertical Horizontal L

Gear Solutions magazine

editor@gearsolutions.com
(800) 366-2185 x204

Coop wants to use t

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

6 gearsolutions.com

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 FELLOWS 10-4 GEAR SHAPERS REMANUFACTURED IN 2017

Y ea h , w e ’v e got t h at!

We have the world’s largest stock

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

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

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

GS February 2018.indb 7 1/23/18 12:17 PM

 INDUSTRY NEW TRENDS, SERVICES,

NEWS AND DEVELOPMENTS

AGMA is officially IACET accredited

The International Association for Continuing for AGMA include:
Education and Training (IACET) has • Learning outcomes that are based on
officially accredited the American Gear identified needs and clearly providing to
Manufacturers Association (AGMA). learners. 
Through a rigorous application process guid- • Having established methods to award
ed by the ANSI/IACET Standard, AGMA CEUs and a system to maintain, protect
is now able to offer Continuing Education and provide training records.
Units (CEUs) to students who take a course • Systematically evaluating all learning
through them based on identified learning events and content to ensure they are
outcomes and delivery of those outcomes. providing the best possible learning expe-
AGMA’s education program has added with AGMA for professional development,” rience.
two additional courses for the 2018 sched- said Casandra Blassingame, director of educa- • Having qualified personnel planning and
ule and, in addition to working on a Gear tion for AGMA. “Our students are working conducting their programs.
Manufacturing or Advance Gear Engineering very hard on their professional goals, and we Students will need to check with their spe-
Certificate, participants will have the oppor- are dedicated to making sure AGMA educa- cific regulatory boards and agencies to con-
tunity to obtain CEUs based on qualified tion counts. Having this accreditation just firm that the IACET CEUs will be accepted
contact hours for a class. With an expanding further proves why our gear classes are the toward maintaining P.E. licensure. AGMA is
program, AGMA is able to provide students a best in the industry, and we are excited to now included in a list of approved providers on
way to measure and quantify the continuing have been awarded this ‘Gold Seal’.”  the IACET website.  
education they are investing in.   According to IACET, “IACET Accredited All courses listed on the AGMA website
“We wanted to provide our students with Providers are an elite group of educators dedi- will have CEU information for students. All
a quality learning experience by adhering to cated to quality in continuing education and further information regarding the CEUs, who
adult education industry standards and the training…and have been thoroughly assessed accepts them, and about IACET can be found
opportunity to use the education they receive by a third party.” Some of the qualifications at www.iacet.org. 

FOR MORE INFORMATION: www.agma.org

New year, new services added to Solar Atmospheres of Western PA

In a continuing quest to enhance customer ratories. Due to shipping and transporting
service, Solar Atmospheres of Western PA test specimens to these laboratories, a delay
has expanded its wings by adding another of 24 to 48 hours before the lab even
type of mechanical testing to its repertoire: received the specimens was normal. With
tensile testing. Tensile tests are essential a keen ear to customers’ needs of receiving
in determining and understanding the tensile results faster and more efficiently,
ultimate strengths of materials. Currently, Solar Atmospheres of Western PA set out
many aerospace specifications demand at on an improvement initiative to bring ten-
least one tensile test to be performed on sile testing in house. Last summer, Solar
each heat lot of material and/or for every took delivery of a new Tinius Olsen 300SL
furnace load of components being heat- Universal testing machine and installed it
treated. Tensile testing is not only more in a temperature-controlled environment.
prevalent today but is often the mechanical In addition, in order to custom machine
test of choice that supersedes all others for test specimens, Solar Atmospheres of
the acceptance of properties. Western PA purchased a new Haas Model
The Tinius Olsen 300SL Universal testing machine Solar Atmospheres has traditionally out- TL-1 CNC lathe. Both units are physi-
allows the company to provide tensile results faster sourced all tensile testing by using excel- cally located in a new 10,000-square-foot
and more efficiently. (Courtesy: Solar Atmospheres) lent locally accredited independent labo- facility adjacent to its 75,000-square-foot

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

8 gearsolutions.com

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 state-of-the-art vacuum heat-treating pro- The Nadcap audit went extremely well wanted faster turnaround on their heat-
duction facility. and final approval was completed on treated components. By bringing this new
Solar Atmospheres of Western PA has December 20, 2017. “We at Solar listen destructive mechanical test in house, we
added room-temperature tensile testing to our customers very carefully. Our cus- will be able to do just that,” said Bob Hill,
to the scope of its Nadcap accreditation. tomer feedback was very definitive: they president.

FOR MORE INFORMATION: www.solaratm.com

DMG Mori USA appoints new president

DMG MORI USA has announced the support to DMG Mori’s valued customers FOR MORE INFORMATION:
appointment of James V. Nudo as the new while continuing to grow its existing rela- www.dmgmori.com
president of the organization as of December tionships within the industry.
7, 2017. Nudo has been with the company
for more than 14 years and has served as
executive officer of DMG Mori USA and
executive officer of the International Legal
Department and International Human
Resources Department for DMG Mori CO.
Ltd. Nudo was part of the team responsible
for implementing the DMG Mori joint ven-
ture from its inception through the present.
Under his direction, the company says it
will continue to deliver the highest level of
customer service and the latest machine tool
technology through its direct sales approach.
Moving forward, the collective goal is to
strengthen the stable foundation built in the
United States within the past years. Nudo
will be integrating strategies for providing

James V. Nudo,
president,
DMG Mori USA
(Courtesy:
DMG Mori)

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 Turbo Lab’s Turbomachinery & Pump Symposia sees another record year
The Turbomachinery Laboratory at Texas
A&M University hosted another record-
breaking Turbomachinery & Pump
Symposia despite a three-month delay due
to Hurricane Harvey.
The 45th Turbomachinery and 33rd
International Pump User’s Symposia (TPS
2017) was originally scheduled for September
12-14, with short courses on September 11.
Due to the impact of Hurricane Harvey on
Houston and surrounding areas, the Turbo
Lab announced on August 29 that the event
would be rescheduled for December 12-14,
with short courses on December 11.
Undeterred by the reschedule, TPS 2017
attracted 89 new companies to the George
R. Brown Convention Center, topping last
year’s record by 10 companies. In total,
the exhibition hosted 359 companies,
just one shy of last year’s record-setting
360 companies. The exhibition spanned
216,000 gross square feet, featuring full-
size equipment and emerging technology
and industry trends from leading tur-
bomachinery, pump, and related organiza-
tions. Eighty-eight percent of the exhibit
f loor for TPS 2018 is already reserved.
TPS 2018 is set for September 18-20, with
short courses held in conjunction with the
Exhibits and technical sessions kept more than 4,600 delegates busy at TPS 2017 in Houston. (Courtesy: Turbo Lab)
symposia on September 17.
4,620 delegates representing 46 countries
visited the exhibition or attended technical as couplings, bearings, gearboxes, dry gas saw great success, despite needing to resched-
sessions. Engineers and technicians, from seals, and annular seals. ule the event with just two weeks’ notice.
novice to experienced, chose from a com- Technical content from TPS 2017 will We know this would not have been possible
bination of 15 short courses, 23 lectures, 16 be available June 2018. Proceedings from without support from our industry partners,
tutorials, 23 discussion groups, and 21 case previous symposia are free for download at as well as our Houston vendors.”
studies. The technical program is selected turbolab.tamu.edu/proceedings. Dr. Dara W. Childs retired December 13
by the turbomachinery and pump advisory “We are grateful to all of our authors, lead- from his post as director of the Turbo Lab
committees and led by experts in their ers, delegates, exhibitors, and advisers who and chair of the TPS advisory committees.
disciplines. Topics included compressors, make TPS a staple event for the industry,” He was honored with a banquet dinner dur-
steam and gas turbines, expanders, pumps said Greg Gammon, director of operations ing the symposia. The search for the Turbo
and drivers, and auxiliary equipment such for the Turbo Lab symposium office. “We Lab director is under way.

FOR MORE INFORMATION: www.tps.tamu.edu

Career opportunities at Forest City Gear

Forest City Gears, founded in 1955, has from tractors to aircraft, exam tables to The business development leader candidate
developed a reputation as a world-class prosthetic limbs, and telescopes to the should have manufacturing industry and
manufacturer of fine and medium pitch Mars Curiosity Rover. Forest City Gear sales supervisory experience to grow sales.
custom gears. Its commitment to quality, even produces gears for its competitors. Controller candidates must have strong
innovation, and service is the reason it is The company is hiring for a controller accounting skills and extensive experience
trusted to produce gears for everything and a position in business development. in a manufacturing environment.

FOR MORE INFORMATION: www.forestcitygear.com.

10 gearsolutions.com

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 MIT launches MITx MicroMasters in principles of manufacturing
MIT announced the launch of the Institute’s through the  Singapore-MIT Alliance for control, manufacturing systems, engineering
third MITx MicroMasters program, in prin- Research and Technology. This master’s pro- management, and supply chain planning and
ciples of manufacturing. The new program gram provides a launchpad for graduates to design. Each course runs for eight weeks, and
brings an advanced manufacturing curricu- become innovative future leaders in estab- students who complete the entire curriculum
lum to the MITx platform for the first time lished manufacturing firms and new entre- and earn their MicroMasters credential will be
and enables learners worldwide to advance preneurial ventures. The  MITx  Principles eligible to apply to the Master of Engineering in
their careers by mastering the fundamental of Manufacturing MicroMasters program Advanced Manufacturing and Design degree
skills needed for global manufacturing excel- leverages this curriculum. program on campus at MIT.
lence and competitiveness. The  MITx  Principles of Manufacturing The Rochester Institute of Technology
New manufacturing firms are grow- MicroMasters curriculum consists of eight (RIT) will also offer a pathway to its Master
ing at their fastest rate since 1993, as online courses, which span the fields of process of Science in Professional Studies that awards
technology revolutionizes the field.
The  MITx  Principles of Manufacturing
MicroMasters program focuses on broad-
based concepts that underlie all manufac-

The
turing environments, putting graduates of
this program in a position to leverage the

Power
industry’s fast-paced growth. The graduate-
level program enables engineers, product
designers, and technology developers to

of One2
advance their careers in a broad range of
engineering capacities, including manufac-
turing, supply chain management, design,
and product development.  
“Throughout an entire undergraduate Your Objective:
degree program, the conventional engineer- One face in perfect alignment with another. For infinity.
ing curriculum teaches students that every-
thing is certain, and results are exact, ignoring
inherent uncertainty,” said David Hardt, a
professor of mechanical engineering at MIT.
“All too often, people fail to get products,
and even companies, across what’s known as
the valley of death, which is the gap between
small-volume and full-scale production. Their
efforts fail because they haven’t been given the
fundamental skill set for managing uncertain-
No problems. No distress. No delays.
ties associated with production rate, quality, That’s the same objective you have for choosing your gear producer.
Circle Gear’s objective is to engage with every customer’s objectives.
and cost. And, that’s exactly what we do in
this new program.”    One to 1000 gears
Noting the continued evolution of technolo-
 Customer designed or reverse engineered
gies, instability of supply chains, and introduc-
tion of new production processes, Hardt said  Gearbox repair, rebuild or redesign
that manufacturing technologies “change so  OEM or end-users
quickly that unless students master the cohe-  ISO 9001:2015 Certified
sive set of fundamentals that underlie produc-
tion, they won’t know how to handle many of
the unexpected challenges that arise.” 1501 S. 55th Court, Cicero, IL 60804
By maintaining a technology-agnostic curric- (800) 637-9335
ulum and embracing the fundamental principles (708) 652-1000 / Fax: (708) 652-1100
sales@circlegear.com
that govern manufacturing, the MITx Principles
www.circlegear.com
of Manufacturing MicroMasters curriculum
will maintain its relevance in this constantly Spiral and Straight Bevel Gears (Cut, Ground or Lapped) • Spur Gears • Helical Gears •
changing environment. Long Shafts • Herringbone Gears • Involute and Straight Sided Splines • Internal Gears •
The new MicroMasters program traces Worm and Worm Gears • Racks • Sprockets • ISO Certified
its roots back to the Master of Engineering
Partnering with QualityReducer to provide
in Advanced Manufacturing and Design, Gearbox repair, rebuilding and reverse-engineering.
originally established at MIT in 2001
FEBRUARY 2018 11

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 credit to learners who successfully com- Studies is an innovative open curriculum has been working with  MITx  since early
plete the MITxPrinciples of Manufacturing environment that enables students to cre- 2017, and offers a similar pathway to hold-
MicroMasters credential and are then admit- ate a customized degree path that meets ers of the MITx Supply Chain Management
ted to RIT. The RIT MS in Professional their educational or career objectives. RIT MicroMasters credential.

FOR MORE INFORMATION: www.news.mit.edu

Motion Industries announces organizational changes

Motion Industries, Inc., a lead- He joined Motion Industries
ing distributor of maintenance, in 2011 as senior vice president
repair, and operation replace- after more than 20 successful
ment parts and a wholly owned years at Baldor Electric Co.
subsidiary of Genuine Parts Kevin Storer was promoted
Company, recently announced to executive vice president of
three management changes, U.S. operations and president of
effective December 11, 2017. Mi Mexico, and will maintain
Tim Breen, Motion Industries responsibility for all field branch
president and CEO, announced sales in the United States and
the following promotions: Randy Breaux, executive Kevin Storer, executive Mark Stoneburner, senior Mexico. This change solidifies
Randy Breaux was promoted vice president of vice president of U.S. vice president of industry his position as the leader for field
to executive vice president of marketing, distribution, operations and president segments and business sales and allows the field to move
and purchasing. of Mi Mexico. (Courtesy: development. (Courtesy:
marketing, distribution, and (Courtesy: Motion Motion Industries) Motion Industries)
in an agile, highly coordinated
purchasing. The increased Industries) fashion with respect to operat-
cooperation among these dis- ing efficiently, as well as seizing
ciplines allows the company to future opportunities in a decisive
identify and plan for growing opportuni- 2016, Breaux was promoted to his most manner. Storer began his career with Motion
ties in the industry such as the industrial recent position of senior vice president of Industries in the West Group in 1987, and held
internet of things (IIoT) and automation. In marketing, distribution, and purchasing. significant positions in the company before

12 gearsolutions.com

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 being promoted in 2016 to his most recent Motion Industries in 2016 as corporate account to continue to ensure our leadership posi-
position as senior vice president of U.S. opera- vice president — industry segments, bringing tion and capitalize on opportunities going
tions and President of Mi Mexico. with him 33 years of industry experience. Mr. forward, which in turn will enhance our
Also, Mark Stoneburner was promoted to Stoneburner will continue to share responsibil- customer service even more.”
senior vice president of industry segments and ity for merger and acquisition (M&A) strategy. With annual sales of $4.6 billion, Motion
business development. The addition of the busi- “Our evolving industry offers us the Industries is a leading industrial parts dis-
ness development function to Stoneburner’s opportunity to be proactive in how we part- tributor of bearings, mechanical power trans-
role enables Motion Industries to better lever- ner with suppliers, how we interact with mission, electrical and industrial automation,
age his deep industry experience, as well as his customers, and how we leverage our greatest hydraulic and industrial hose, hydraulic and
strong strategic approach to a growing portion asset — our people,” Breen said. “Each of pneumatic components, industrial products,
of the company’s overall business. He joined these promotions allows Motion Industries safety products, and material handling.

FOR MORE INFORMATION: www.MotionIndustries.com

High Tech is our Business

ALD is a leader in vacuum

process technology and Heat
treatment services.

LEADERS IN THE
CONTROL OF DISTORTION
ALD Thermal Treatment, Inc.
New corporate website from Slater Tools offers user
convenience for hundreds of line items in five product
+ Low Pressure Carburizing
families. (Courtesy: Slater) + High pressure gas quenching
+ Gas Nitriding
New Slater Tools website offers + Ferritic Nitro-Carburizing
convenience, easy navigation + Plasma Carburizing
+ Normalizing
Slater Tools announces it has a new website + Hardening
with user-focused features that enhance the + Annealing
experience and offer convenience, especially + Brazing
for customers and repeat viewers. The com- + Cryogenic Treatments
pletely rebuilt website resides at the same url + Engineering services and
process development
address, www.slatertools.com.
+ Prototype and trials
New to the site new is a “quick quote”
function that allows customers to add items
to a quote/wish list directly from product
pages. A simple click adds the item, and Global Service Centers
doesn’t require the customer to leave the cur-
Enrique Lopez – Sales and Marketing
rent page or section being navigated. Also,  Limbach-Oberfrohna Email: sales@aldtt.net
the new site displays specifications and part Phone +1 (810) 357-0685
Germany
numbers for the entire range of standard
tools, including the new product lines of Go/  Port Huron, Michigan
ALD Thermal Treatment, Inc.
NoGo gages (plug and ring) and indexable USA 2656 24th Street
punch broaching (tools and toolholders).  Ramos Arizpe, Coahuila Port Huron, MI 48060, USA
The website presents information clearly and Mexico
allows users to do a deeper dive to get all infor-
mation. The new site also offers tremendous www.aldtt.net
resources including instructional videos and
collateral, technical support such as speed and
feed recommendations, and also highlights the
ALD is a subsidiary of AMG Advanced Metallurgical Group N.V.
many services provided like reverse engineering
and gage certification.
FEBRUARY 2018 13

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 Hannover Messe USA to premier in Chicago in September
Hannover Messe is the world-renowned up with the latest trends and developments Messe Managing Board Chairman Jochen
trade show brand synonymous with indus- in industrial digitalization. This strong Köckler. “We now want to leverage the
trial innovation, key trends, and busi- profile has yielded steady growth in the power of the Hannover Messe brand to
ness leads. The event has made a name show’s German and international exhibitor speed up growth in our foreign markets.
for itself as a global hotspot for Industry and visitor following. This year, more than Therefore, we are premiering  Hannover
4.0 technologies. CEOs of global corpo- half of Hannover Messe’s exhibitors, and Messe USA  co-located with IMTS
rations, managers of SMEs, and leaders some 70,000 of the show’s visitors, came September 2018 in Chicago.”
of the world’s major industrial nations from outside Germany. Internationalizing its strong, German-
use  Hannover Messe  (currently staged “There is no other trade show brand like grown trade show brands is a strategy
annually in Hannover, Germany) to keep it anywhere in the world,” said Deutsche Deutsche Messe has been successfully
pursuing for many years, and the com-
pany now stages some 60 events outside
Germany every year. The bulk of these

Why ETC?
are industrial trade shows, dealing with
specific sectors such as industrial robotics,
factory automation, energy technology,
and industrial supply.
Deutsche Messe has had a presence in
the U.S. market for many years and has
been running trade shows in Chicago since
2012. Starting in September, it will now
cluster these Chicago-based shows under
NEW and RECONDITIONED
NEW RECONDITIONED
CUTTER BODIES for Sale.
the brand name “Hannover Messe USA.”
“As a brand, Hannover Messe has been
steadily adding to its acclaim in the U.S.
market, in part thanks to the country’s
Partner Country showcase in 2016 —
a momentous event attended by (then)
President Barack Obama,” said Köckler.
“By launching Hannover Messe on U.S.
soil, we hope to attract even more exhibi-
tors and visitors to Chicago while also
generating positive spin-off effects for
Hannover Messe at its home base in
Hannover, Germany.”
The premiere of Hannover Messe USA
is expected to attract about 550 exhibi-
tors and more than 100,000 visitors and
will occupy about 130,000 square feet of
Customer Service, Speed, Quality, & Value display space. For comparison, next year’s
Hannover Messe in Hannover, Germany,
is likely to attract more than 5,000 exhibi-

ETC
tors and about 200,000 visitors.
Choose the stick that works, “Our trade shows outside Germany are
cause work doesn’t stop! aimed exclusively at local and regional
visitors,” Köckler said. “Our trade shows
2710 West Caro Rd. in Hannover, Germany, on the other hand,
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www.imts.com

14 gearsolutions.com

GS February 2018.indb 14 1/23/18 12:17 PM

 American Jenny Blackford

Gear Manufacturers Leah Lewis of

Vice President
Communications
Manager of Meetings
Association AGMA

AGMA/ABMA Annual Meeting

can help build your network
According to LinkedIn, 80 per- Will it Come to an End?
cent of professionals consider and Next Steps: Automobile
networking to be a significant Manufacturing and the
driver of career advancement and Economic Consequences
success. While many profession- • Brett Smith, co-director
als view networking as a tool to for Center for Automotive
be used solely for personal career Research (CA R):  The
growth, it can be even more valu- Automobile: Unprecedented
able for senior executives and Change, But at What
business owners to stay connected Speed?  and Next Steps:
with industry peers. Automobile Manufacturing and
Your professional network the Economic Consequences
serves as the ideal soundboard • Curt Stenhorst,  con-
to exchange ideas, ask for advice sumer trends expert and found-
about issues you may be facing, er/CEO of Focuswise: Thriving
and stay on top of the latest technologies and make your rounds and have discussions in the Age of Distraction
innovations. The AGMA/ABMA Annual while it’s calm and quiet. • Arun Sundarajun, New York University-
Meeting was designed to help members • Focus on relationship building: While Stern School of Business: Capitalizing on
build and sustain valuable connections in your first instinct at a networking event the Sharing Economy and Rise of Crowd-
the industry. This annual event is a great might be to jump into a sales pitch, try to Based Capitalism
place to meet with like-minded professionals focus your efforts on genuine conversa- We hope to see you April 26-28 in Naples,
and suppliers to add value to your business. tion. Be yourself and be authentic. Florida. Register at www.agma.org or www.
Join us April 26-28 in Naples, Florida, and • Take advantage of the First Timers americanbearings.org.
start building your network of peers. Reception: If you are new to the AGMA/
For first-time attendees, the thought of ABMA Annual Meeting, you can’t miss Thank You AGMA/ABMA Committee
building a professional network can seem the First Timers Reception on April 26.
daunting, but there are simple steps you can Exclusively for first-time attendees, this • Chair, David Goodfellow, Star SU, LLC
take to make the process of networking more reception matches new guests with seasoned
comfortable for those new to the process: meeting veterans to answer your questions AGMA Participants
• Dress the Part: Check the event dress about the meeting and introduce you to
code in advance to ensure you blend in their network. • Jim Bregi, Doppler Gear Company
with the group. Not only will this make In addition to the ample opportunities to • Dean Burrows, Gear Motions Inc.
you instantly feel less awkward, but you build your professional network, the AGMA/ • Nitin Chaphalkar, DMG/Mori/Seki USA
will look like you’re an Annual Meeting ABMA Annual Meeting is your go-to source • John Cross, ASI Technologies
regular. Check with the event organizers for top tier, innovative industry education. • John Grazia, GearTec Inc.
if you aren’t sure what you should pack. Business presentations at the 2018 event • Dave Long, Chalmers, Kubeck Inc.
• Arrive on time: It may be tempting to include: • Anne Miner, Machine Tool Builders
show up to a reception fashionably late, • J.R. Martinez,  Iraq War veteran,
especially if you are new to the group or actor, motivational speaker:  Adapt and ABMA Participants
don’t know many attendees yet, but arriv- Overcome
ing on time gives you an edge. People may • Jim Meil, principal industry analyst and • Kevin Herkner, Standard Locknut
not be settled into a group conversation economist for ACT Research Co.:  U.S. • Jeff Manzagol, NN Inc.
yet, and it’s a good opportunity to casually Economic Expansion or Extension? Or • Tony Richey, Specialty Steel Treating Inc.
FEBRUARY 2018 15

GS February 2018.indb 15 1/23/18 12:17 PM

 Get Inspired By The 2018 AGMA/ABMA Speaker Line Up

Adapt and Overcome as Uber, Airbnb, Didi Chuxing, Upcounsel, and WeWork — what we
collectively call “the sharing economy” — are examples of a future
J.R. Martinez, Iraq War veteran, actor, and winner of ABC’s where peer-to-peer exchange is increasingly prevalent, and the
“Dancing With The Stars” crowd replaces the corporation as the center of capitalist enterprise.
There is a learning curve to anything, and our Author, professor, and technology consultant, Sundararajan has
ability to adapt in the midst of change is what been invited to bring perspective into the convergence of digital
helps to strengthen our character. Join Martinez and socioeconomic forces that have catalyzed this transition. His
as he shares his life story of constant change that discussion will show how this shift to crowd-based capitalism will
has forced him to adapt to new environments alter economic growth, what it means to have a job, and how all of
and challenges. Walk with him as he explains this will affect our social fabric of being connected to each other.
how his childhood challenges enabled him to
cope with the unexpected following a traumatic
event during his Iraq deployment. Despite his copious injuries and Trade Policy Update and Perspective:
limitations, this unbelievable situation has blessed him with a whole A View from Washington
new perspective on life. During this presentation, Martinez will
Derek Gianino, Director of International Policy, U.S. Chamber of Commerce
encourage each of you to look deeply at your obstacles, embrace
them in a different light, and call upon fortitude and grit when facing International trade became a heated topic of
your challenges head on. debate during the 2016 presidential campaign and
continued during the Trump administration’s first
year. With the focus on re-negotiating NAFTA, the
Thriving in the Age of Distraction business community has been actively working
Curt Steinhorst, Consumer Trends Expert & Founder/CEO of Focuswise behind the scenes to protect and preserve the
benefits from the pact while welcoming the
For the first time in history, we live in a world without opportunity to update, modernize, and improve
any barriers to connection or communication. the agreement. Gianino is prepared to review what the future holds
This has fundamentally altered the way people for trade agreements and trade policy in general. He will share the
work, engage, communicate, and relate to one Trump administration’s goals and objectives on trade, and what all
another. We are asked to process four times of this means for the manufacturing community. In addition, he
the information Americans used to decades ago, will discuss the U.S. Chamber of Commerce’s role as a grassroots
but with less space and time to actually think. organization, promoting international trade agenda to business and
In reality, the same technology that promises to third-party stakeholders.
simplify processes also makes it even more difficult to focus and
reach increasingly distracted customers. Join Steinhorst, a highly
rated 2017 Annual Meeting speaker, as he shares how we regain U.S. Economic Expansion or Extension?
our attention and overcome the challenges we face in our digitally
distracted, constantly connected workplace. This presentation
Or Will It Come to an End?
gives a realistic picture of focusing and how to tackle the attention Jim Meil, Principal, Industry Analysis, ACT Research Co., LLC
barriers, interruptions, and distractions we all face daily. In April 2018, the U.S. economy will be on the
verge of its second longest expansion in the
Capitalizing on the Sharing Economy post-World War II period. If it lasts until the 2019
and Rise of Crowd-Based Capitalism meeting, it will be precedent setting. But what
does all this mean and — more importantly —
Arun Sundararajan, Ph.D. Professor and the Robert L. and Dale Atkins how does it relate to your business now and in the
Rosen, Faculty Fellow at New York University’s (NYU) Stern School of future? As AGMA and ABMA members, you need
Business to recognize economic cycles. Meil’s economic
analysis has become a staple for providing critical data in effective
In the 18th century economy, most business was
business planning. Meil expands his overview this year to include
conducted between individuals — the one-person Information on consumer spending, interest rate projections,
shop and the small business were the heart of international economics, business confidence, investments, and
the economy. Over the next two centuries, we steel/commodity pricing.
witnessed the emergence of the organizational
economy, with most economic activity conducted
in large cohesive companies with managerial
hierarchies and full-time employees. We are now
entering a third phase, transitioning from 20th century managerial
capitalism to 21st century crowd-based capitalism. Platforms such

American
Gear Manufacturers
16
Association
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 Automation in Your Plant — A Practical Some Annual Meeting Events
Discussion NEW! Corn Hole Tournament Florida. Choose from two optional
Robotics and automation have been primarily used by Registration required tours to partake in with your
automobile manufacturers. But as the technology changes, Friday | 1 p.m. – 4 p.m. casual attire AGMA/ABMA colleagues.
and smarter, more agile units are being built — in an ESPN Game Day is coming to
affordable manner — robots are being brought into all sorts of Naples, Florida, to cover the first The Revs Institute Automotive Tour
manufacturing sites. Small and medium-sized manufacturers official AGMA/ABMA Corn Hole (limit 12)
can now consider adding automation to their facility. AGMA Tournament. Grab a teammate, The Revs Institute is the premiere
will bring in experts from top robotics companies to discuss, design your uniforms, and get destination to study and explore
in panel format, current trends in industrial robot and cobot ready to compete in a bracket- one of the largest archives of
use in manufacturing. The panel will discuss the advances in style tournament that will make automotive history ever preserved
computing that have removed the necessity of IT professionals March Madness seem tame. If for scholars and connoisseurs
setting up complex programming and have a practical bean bag tossing is not your thing, alike. The tour is about two hours
discussion on how you can bring automation to your plant floor spectators and cheerleaders are long and features more than 100
and see benefit in the short term. A complete list of panelists welcome to join in for the amazing rare automotive innovations.
is available on the AGMA website. food and side-line activities. Prizes
will be awarded throughout the Florida Mangrove Eco Tour
The Automobile: Unprecedented Change, tournament, so bring your A-game
and team spirit.
The Conservancy of Southwest
Florida will host AGMA/ABMA
But at What Speed? guests for a guided nature walk
Brett Smith, Assistant Director, MET, Co-Director, Conference Friday Night Arcade Adventure on the half mile Briggs Boardwalk.
Strategy, Center for Automotive Research (CAR) Friday | 7 p.m. – 10 p.m. casual attire View the unique Florida mangrove
Join the AGMA/ABMA attendees trees, whose roots grow
With seemingly unprecedented sudden-
as we transform the Naples Grand submerged in water, and the
ness, 2017 was the year of technology
awakening for the automotive industry. An ballroom into an Arcade Adventure. chance to see local birds, reptiles,
industry traditionally based on a methodi- Who can resist Skee-Ball, Air and plants. Comfortable walking
cal pace of innovation and change is now Hockey, or Pac-Man with your shoes are recommended.
facing a revolution. It is a certainty that friends and colleagues? Now in
the automated, connected, and electrified the 21st century, we will be adding Night of Comedy
(ACE) technology will drastically change the some virtual reality challenges Saturday | 6:30 p.m. – 10 p.m.
automobile and the industry that builds it. The future of the into the evening along with a lot business attire
combustion engine has become, and will continue to be, a of new and exciting opportunities Let’s celebrate our last night
paramount topic among those companies representing the and adventures. The evening will together in grand style with dinner
powertrain industry. Expert and strategic planner Smith will include a casual dinner, several and a lot of laughs. Comic Wayne
share his vision as an insider in the automobile research comfort food stations, and ample Cotter will be returning to the
arena. His background as the chairman of CAR’s manage- opportunities for everyone to AGMA/ABMA center stage to
ment briefing seminars on the car of the future brings his participate at various games. provide the night’s entertainment.
trained and qualified perspective to this critical topic. Once a computer engineer,
Local Tours Cotter is now a favorite of the talk
Registration required (limited space) show circuit and is returning to
Next Steps: Automobile Manufacturing Saturday | 1:30 p.m. – 3:30 p.m. the Annual Meeting as a repeat
and the Economic Consequences casual attire performer. The evening will
Spend your afternoon getting to include a reception, dinner, and
Jim Meil and Brett Smith know the local area of Naples, awards presentation.
After the presentations from Meil and Smith,
join them for a robust point/counterpoint
discussion that could answer some Be A Sponsor For The Annual Meeting
questions, raise new ideas, or trigger alarms Are you going to attend the Annual meeting and in the onsite program.
about coping with a potential revolution in Meeting? Wouldn’t you like your The earlier you sponsor, the more
manufacturing. We all recognize that the logo to be visible for all to see? times your logo will be seen.
automobile industry will not look like it does Sponsor one of the many parts to
today. What we don’t know is how fast it • Printed signs and video screen
the Annual Meeting and get your recognition during the event.
will change, who will be most affected, company name out there.
and who will our consumers be. This final • Specific recognition for the item/
All sponsors will receive: event.
session will integrate the key points from the
shared economy session and synthesize all • Company logo on the annual Visit www.agma.org/events/agma-
three components into a dynamic, thought- meeting web page with links to your abma-annual-meeting/ to see the
provoking discussion that will be one of the company's website from the time of spaces available and fill out the
highlights of the 2018 Annual Meeting. securing the sponsorship through sponsorship form to get started.
the post-meeting press activities. Please contact Leah Lewis for any
• Your company's logo will be sponsorship inquiries at lewis@
printed in all materials for the agma.org.

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

1001 N. Fairfax Street | Suite 500 | Alexandria, VA 22314 | (703) 684-0211 | www.agma.org
FEBRUARY 2018 17

GS February 2018.indb 17 1/23/18 12:17 PM

 CALENDAR OF EVENTS
Whether you’re looking for technical education, networking opportunities, or a way for your voice to be heard
in the standards process, AGMA has something to offer you. If you would like more information on any of the
following events, visit www.agma.org or send an email to events@agma.org.
Events are open to AGMA members only. Not a member? Send an email to membership@agma.org.

February 15 — Metallurgy and Materials Committee Meeting — WebEx

February 16 — Nomenclature Committee Meeting
February 19-20 — Spline Committee Meeting — Chicago, Illinois
FEBRUARY

February 21 — Fine-Pitch Gearing Committee Meeting — WebEx

February 22 — Gear Accuracy Committee — WebEx
February 22 & 23 — Steels for Gear Applications Class — Mumbai, India
February 27 — Helical Gear Rating Committee – subcommittee 925 Meeting — TBD
February 28 — Cutting Tools Committee — WebEx

March 1 — Lubrication Committee Meeting — WebEx

March 2 — Wormgearing Committee — WebEx
March 5 — Bevel Gearing Committee Meeting — WebEx
March 7 — Fine-Pitch Gearing Committee Meeting — WebEx
MARCH

March 8 — Nomenclature Committee Meeting — WebEx

March 9 — Emerging Technology Committee Meeting — WebEx
March 13 — Metallurgy and Materials Committee Meeting — WebEx
March 14 — Helical Gear Rating Committee – subcommittee 925 Meeting — WebEx
March 20-22 — Gearbox CSI — Concordville, Pennsylvania
March 21 — Computer Programming Committee — WebEx

AGMA LEADERSHIP

Jim Bregi: Chairman Nitin Chaphalkar: DMG Mori USA

EXECUTIVE COMMITTEE

Doppler Gear Company

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

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

Jenny Blackford: Vice President, Marketing Brian Schultz: Great Lakes Industry, Inc.
Jill Johnson: Director, Member Services George Thomas: Bison Gear & Engineering Corp.
Casandra D. Blassingame: Director, Education Hastings Wyman: Klingelnberg America, Inc.
General requests: webmaster@agma.org | Membership questions: membership@agma.org | Gear Expo information: gearexpo@agma.org
Technical/Standards information: tech@agma.org | AGMA Foundation: foundation@agma.org

18 gearsolutions.com

012018
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GS February 2018.indb 19 1/23/18 12:18 PM
 MATERIALS
MATTER
MIKE BURNETT
TECHNOLOGIST, TIMKENSTEEL

CONTROLLING DISTORTION BY CHOOSING THE RIGHT MATERIALS

Distortion effects can have a major impact on manufacturing costs and overall
gear quality. One way to mitigate distortion involves in-depth material knowledge.
Perhaps the most costly factor in the manufacture of high-precision • Superior chemistry control to minimize hardenability variations
components like gears is that of unplanned dimensional changes or within a heat and from heat to heat. This is a critical parameter
distortion of the final part. Often distortion is not discovered until in reducing heat-treat distortions.
the part has progressed through the entire manufacturing process • Knowledge and selection of casting variables to minimize chemical
with all the associated material, machining, heat-treating, and segregation, including appropriate reduction ratio, optimized cast-
finishing costs embedded. When it is found at this point that the ing parameters, bloom rolling, and processing.
dimensional requirements are not met, they are typically uncorrect- • Post-hot working process optimization to minimize residual stress in
able. This discovery results in scrapping of the finished gear, with a blanks, including a uniform heat-treating process, elimination of
loss of all the manufacturing costs. stresses from further processing, etc. Also important is develop-
Achieving the dimensional requirements requires precise control over ment of machinable material condition to minimize introduction
all aspects of manufacturing, as is shown in the diagram in Figure 1. of machining stresses.
Whereas the material may not appear to play a significant role from The final desired product is a stress-free steel gear blank that responds
this diagram, it actually affects the response of all the manufacturing consistently and uniformly through the machining and heat-treat
processes and can affect the role of each to achieve the final print processing to produce a dimensionally stable and accurate final gear.
dimensions. Gear manufacturers dedicate significant resources to The largest potential source for dimensional changes and distor-
understanding and controlling as many of these variables as pos- tion during gear manufacturing is the final heat-treatment process
sible; however, the material parameters are largely controlled by the to develop the necessary properties. The phase transformations that
steel and blank source, and are not entirely controlled through the typically occur during heat treatment are accompanied by volume
material specifications. The material specification for the gear blank changes, and the thermal profiles introduced are also sources for
typically only covers the basic attributes associated with meeting the dimensional changes, including distortion. Major efforts are typically
necessary properties in the final part, and does not fully address all deployed to minimize these shape changes, and in particular non-
the factors that can influence the dimensional stability of the mate- uniform changes, through initial part design, material specifications,
rial to influence the final gear shape. This article will discuss the minimization of stresses in the green gear blank, and fixturing of the
material variables that can influence the dimensional stability of the parts along with devising the heat-treatment parameters to ensure as
gear as it is being manufactured into the final shape. uniform and consistent a process as possible. However, there are still
Dimensional control of a gear blank requires precise regulation of potential sources for non-uniformities in the raw material that can
the process from the beginning of the material sourcing and process- manifest themselves in heat-treat distortion. These can be a result
ing through the final heat treating, machining and finishing steps, of numerous factors, but can include:
and includes the following: • Compositional segregation in the raw material that result in non-
uniform transformations.
• Non-relieved, variable stresses that are relieved during heat-treatment.
• Excessive variations in composition or hardenability within a heat
or between heats.
• Grain size variations that result from insufficient/inconsistent
grain boundary pinning additives.
Here again, the raw material provider has control over and
responsibility to minimize the potential impacts of these effects, and
plays a vital role in optimizing the material to provide a uniform,
low-distortion heat-treat response to the gear heat-treat process.
Whereas these effects are difficult to specify into the material, it is
important to select a steel provider that understands how to optimize
their steelmaking processes to control and minimize each of these
potential sources of distortion.
The end result is that the gear material provider becomes a partner
with the gear manufacturer in controlling the dimensional stability
The production of ring gears is one example of a distortion-sensitive application that of the final gear application beyond what is specified on the print
can benefit from proper material selection. Above, five-speed ring gears receive
or material specification. Since the material characteristics interact
lubrication holes and packing on the production line at TimkenSteel’s St. Clair plant
in Eaton, Ohio. The facility provides value-added components to automotive and with each manufacturing process step, it is important that the mate-
industrial customers. (Courtesy: TimkenSteel Corporation) rial provider be aware and have an understanding of the influence
20 gearsolutions.com

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 DESIGN
• Alloy procurement HEAT-TREAT
MATERIAL • Alloy selection • Furnace temperature
• Alloy • Part geometry • Preheat
• Quench sensitivity • Heat-up rate
• Prior condition and microstructure • Temperature uniformity PRIOR TO HEAT-TREAT
• Alloy segregation • Non-uniform heating • Machine stresses
• Decarburization • Racking • Cold work
• Transformation induced stresses • Load density • Prior condition and microstructure
• Part-to-part interactions • Grinding stresses
• Carburizing • Shot and grit blasting
• Atmosphere control • Plating for decarburization control

QUENCHING
• Quench temperature TEMPERING FINISHING
• Quench agitation • Furnace temperature • Machining
• Type of quenchant POST-QUENCH • Preheat • Grinding
• Contamination • Part handling • Heat-up rate • Pickling
• Racking • Delay before tempering • Temperature uniformity • Shot and grit blasting
• Load density • Washing temperature • Non-uniform heating • Straightening
• Part-to-part interactions • Wash velocity • Racking • Plating
• Handling during quench • Uneven cooling • Load density • Baking after painting
• Temperature at withdrawal • Refrigeration • Part-to-part interactions • Stress relief
• Fixturing
Figure 1: Fishbone diagram of the potential causes of residual stresses and distortion (1).

that the material can have on each operation, and be prepared to influence resulting from the response of the gear to the final heat-
further optimize the material/blank to minimize the final distortion. treatment process. Optimization of the material compositional and
Further, it is imperative that the material provider have the capability hardenability control, segregation and internal consistency factors,
to investigate and determine the root cause for material anomalies residual stresses introduced during manufacturing and a machinable
or issues that occur during manufacturing process steps to be able condition for gear cutting are all factors the material provider has to
to offer potential solutions to the gear manufacturer. have knowledge and capability to control to produce a dimensionally
Several of the previous Materials Matter columns (June, September, stable heat-treated final gear product. Many of these factors go beyond
October, and December 2017, January 2018) illustrate the necessary what can be controlled in material specifications, and requires the
capabilities the material supplier should possess, including a knowl- selection of a superior and knowledgeable material provider who can
edge of machining of gears (such as broaching), heat-treat response work as a partner with you in achieving minimal distortion. 
of gears through various hardening processes (including vacuum
carburizing), investigative support to determine root cause analysis REFERENCES
of issues that occur, and modeling techniques to understand and 1. Mackenzie, D., Heat Treatment of Gears, Conference: Conference:
control manufacturing processes to ensure the consistency of our Heat Treatment 2005: ASM 23rd Heat Treating Conference,
final products. These engineering resource investments into materi- Pittsburgh PA.
als manufacturing process and support define the capabilities of a 2. Common Gear Failures, A. Koutsis, Gear Solutions, June 2017.
premier steel supplier into the gear industry. 3. Materials Modeling for Better Gear Design and Performance,
P. Anderson, Gear Solutions, Sept 2017.
SUMMARY 4. Use of Clean Steels, T. Zorc and M. Burnett, Gear Solutions,
Distortion effects can have a major impact on manufacturing costs October 2017.
and overall gear quality. Whereas there are many potential sources 5. Enhanced Steel Performance during Vacuum Carburizing of
for distortion, the material factors can interact with each source, and Gears, P. Anderson and M. Burnett, Gear Solutions, December
influence the magnitude of each on the final product dimensional 2017.
control. The material manufacturing methods can introduce numerous 6. Machinability and the Cost of Manufacturing Gears, M.
potential direct or indirect sources for distortion, with the primary Burnett, Gear Solutions, January 2018.

ABOUT THE AUTHOR  Mike Burnett is a technologist at TimkenSteel. Learn more at www.timkensteel.com.

FEBRUARY  2018 21

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 TOOTH BRIAN DENGEL

TIPS
GENERAL MANAGER
KHK-USA

WHAT ARE YOU MADE OF?

Different materials make gears suitable for the desired application.
The key involves identifying the right recipe.
If you have ever sat down for Sunday dinner in an authentic this requirement that most worms are made from carbon or alloy steel
Italian-American home, you know not to question the red sauce and most worm wheels are made from bronze, cast iron, or aluminum
known as “Grandma’s Gravy.” This tomato-based elixir coating bronze. Consider a 60:1 worm gear pair. In this arrangement, the
your pasta is a gift from heaven itself. But the ketchup served with worm will be rotating one tooth in and out of mesh continuously.
your French fries at the local fast food drive-thru is also a “sauce” However, the worm wheel will be engaging just one tooth every
made from tomatoes. Therefore, they must be interchangeable, revolution. Therefore, each tooth of the worm wheel has a duty cycle
right? Absolute sacrilege! However, this same type of comparison of one worm revolution engaged and 59 revolutions disengaged. This
occurs all too frequently with gear materials; there are certain implies that the worm needs to have a durability 60 times greater
materials that are universally suitable for gearing, but others that than that of the wheel. If the wheel was produced from a material
are only appropriate for specific applications. that has the same durability as the worm, the worm would fail in an

GEAR RACKS
Gear racks are most frequently produced
from carbon steel. This is a very suitable
material for racks in most environments and
under most use conditions. The reason that
this material works well is due to the relative
strength of the rack tooth in combination
with the pinion. In almost every application,
the pinion is inherently the weaker member
in the mesh and will fail long before the rack.
The material also lends itself to being heat-
treated for additional strength, permits the
addition of threaded or bolt holes, maintains
dimensional stability, and can be straight-
ened if necessary. For wash-down or in food
environments, stainless steel is frequently
used. This material shares all the attributes
of carbon steel except for the ability to be
heat-treated for additional strength. In some
applications, the need for the rack to be
self-lubricating or to reduce system weight,
a plastic rack is used. These racks are very
durable and useful only when selected for the
proper environment. For example, an acetal
rack will not maintain its straightness over a Bevel gears are typically used in high torque environments and are therefore usually produced from carbon steel,
long length (> 1 meter), and is known to have stainless steel, or alloy steel. However, there are applications where acetal or nylon bevel gears are suitable, such
the possibility of voids. This makes adding as R/C helicopters, hand-crank applications, or for mass-produced toys. (Courtesy: SPD/SI)
boltholes or threaded holes a risk. Alternately,
a nylon rack will not maintain its dimensional accuracy when exposed accelerated manner due to scoring. This is a condition that occurs
to varying temperatures or changes in humidity, as this material reacts when metal-to-metal contact causes the tooth flanks of the gears to
to both temperature and moisture. For a direct replacement, based on weld together. This process pulls metal from the pair and begins to
the relative tooth strength, a nylon gear rack will need to be 6x larger scratch the tooth surface in the sliding direction. Although proper
than a carbon steel rack in order to handle the same loading. lubricant can minimize scoring, using materials that allow for heat
dissipation is the better design consideration.
DRIVE GEAR
For gearing that operates as a friction mechanism, such as a worm BEVEL GEARS
gear pair, it is critical that the drive gear have a surface strength Bevel gears are typically used in high torque environments and are
(durability) that is greater than that of the driven gear. It is because of therefore usually produced from carbon steel, stainless steel, or alloy
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 steel. However, there are applications where acetal or nylon bevel ACETAL GEARS
gears are suitable, such as R/C helicopters, hand-crank applications, Acetal gears are typically the most economical, as they are generally
or for mass-produced toys. Plastics can be used to produce straight injection molded. The moderate cost of raw material and low cost
tooth bevel gears, but they cannot be used to produce spiral bevel, of machining make this a common material for prototyping. Acetal
zerol bevel, or hypoid bevel gears, as the material would deform is a very dimensionally stable plastic due to its low absorption of
because of the heat generated by the cutting process. moisture. It is recommended that acetal gears not be subjected to
shock loading as they are less resilient to impact. Nylon gears are
SPUR GEARS common in power transmission applications due to the material’s
Spur gears are the most popular form of gearing and can be moderate cost, the ease of machining, the material’s self-lubricating
produced in almost any material. Gears produced 100 years ago properties, and its vibration absorbing abilities. Nylon gears are
were typically produced from cast iron. This was an economical sometimes made from a reinforced nylon. Depending on the reinforc-
method for producing change gears for industrial equipment. ing material, a nylon gear can improve its bending strength by 30
Materials commonly used today are various types of steel, plastic, to 90 percent. Fiberglass-filled nylons maintain the self-lubricating
and specialty metals. and weight-saving properties, reduce the dimensional growth due to
temperature and moisture, and increase the bending strength by 30
CARBON STEEL GEARS percent, albeit at a 50-percent increase in raw material cost. Carbon
Carbon steel gears are economical and suitable for most applica- fiber-filled nylons also maintain the self-lubricating and weight sav-
tions. Carbon steels offer moderate strength, low cost, and ease ing properties, greatly reduce the growth due to temperature and
of machinability. Stainless steels also offer moderate strength moisture, and increase the bending strength by 90 percent. However,
and ease of machinability but at a higher material cost. Some the raw material cost is at least 600 percent more expensive than
stainless steels are also non-magnetic. Alloy steels offer superior unfilled nylons.
strength and can be hardened for superior durability but at a Spur gears are also produced from titanium, Inconel, and other
high raw material cost. All carbon steels, some stainless steels, exotic alloys for classified military and space applications.
and most alloy steels can be heat-treated to improve surface As detailed in the examples above, there are many distinct materials for
durability. All steels are dimensionally stable and suitable for gearing. Each has a purpose and each application will dictate what material
keyways and tapped holes. should be selected. So please don’t put ketchup on your spaghetti. 

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

RUSSELL, Precision Gear Products

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FEBRUARY  2018 23

GS February 2018.indb 23 1/23/18 12:18 PM

 HOT D. SCOTT MACKENZIE, PHD, FASM

SEAT
SENIOR RESEARCH SCIENTIST-METALLURGY
HOUGHTON INTERNATIONAL INC.

OIL QUENCHANTS – UNDERSTANDING THE CHEMISTRY (PART II)

This installment explores the chemistry of base oils, particularly as they affect quenching
performance, to be followed in March by a discussion of quench oil oxidation.
In this installment we will focus on base oils. Engineered quench oil is 125

governed by the desired quenching performance; the necessary thermal and

120
oxidative stability, and finally price or market considerations. Quenching
performance is generally considered to be the heat transfer characteristics 115

and the thermal stability of the oil. This includes having an acceptable

Maximum Cooling Rate (°C/s)

110
flash temperature that is approximately 50°C above the expected use
temperature; low sludge forming tendency; long life; and the necessary 105

quenching speed. The best quench oils have the following characteristics: 100
• The maximum cooling rate to achieve maximum hardness and
depth of hardening. 95

• Minimal formation or deposition of sludge. 90

• Maximum thermal and oxidation stability (achieved through the

additive package). 85

At present, this currently favors mineral oils. 80

0.85 0.88 0.91 0.94 0.97 1.00
The base stocks of oils used in the formulation of quench oils are Contact Angle (COS Ɵ)

complex. They contain various ratios of paraffinic and naphthenic con- Figure 1: Relationship between the “wettability” of an oil and
stituents, as well as numerous open chain and cyclic derivatives such as the maximum cooling rate (Totten, Bates, & Clinton, 1993).
sulfur, oxygen, and nitrogen heterocycles. The specific composition of the
base oil depends on the source of the crude oil. The various ratios of the n-alkanes, which are chemical compounds that consist of only carbon
constituents are a “fingerprint” of the oil, enabling identification of the and hydrogen. Alkanes are also known as paraffins. The low temperature
source of the crude oil (oil field). behavior of naphthenic oils is better than same viscosity paraffinic oils,
As was inferred from the previous paragraph, the composition of so the naphthenic oils tend to have a lower pour point. The degradation
quench oil affects the quenching performance. Because of local differ- products of naphthenic oils tend to be more soluble in oil, which can
ences in composition, quench oil can exhibit a wide variation in thermal contribute to greater staining. For the same viscosity, naphthenic oils tend
and oxidative stability, and a wide variation in quenching speed. When to oxidize at a faster rate and have a lower thermal stability. Naphthenic
you add the thermal stability and speed improver additive packages, grades, at the same viscosity as a paraffinic grade, also tend to have a lower
an even wider variation in cooling rates and thermal stability occurs. flash temperature.
From a supplier’s perspective, this means different Paraffinic oils are oils that consist predominately of
PARAFFIN
additive packages or different ratios of anti-oxidants long chains of hydrocarbons, called alkanes. Because
and speed improvers may be necessary to provide an of these long chains, when compared to naphthenic
oil that behaves identically across the world. oils, paraffinic oils are widely used for lubrication
The volatility of quench oil is inversely propor- base stocks. They are also the preferred base stock for
tional to the flash point of the oil. The volatility oil-based quenchants. Comparing identical viscosities
decreases as the average molecular weight increas- of naphthenic and paraffinic oils, paraffinic oils have
es. As a general rule, the volatility decreases and higher flash temperatures, superior cooling curves,
flash temperature increases as the viscosity of the and better oxidation and thermal stability. This
oil increases. This viscosity is related to the average means that they tend to stain less and last longer. A
molecular weight. comparison of the structures of paraffin and naph-
The quench severity of oil is directly related to the thenes are shown in Figure 2.
“wettability,” measured by the contact angle between There are many methods to produce the oil base
the part and the quench oil. As the viscosity increases, stock. Some of the most common methods for com-
the contact angle decreases, which in turn decreases mercially available quench oils are:
the cooling rate. The various additive packages avail- • Double hydro-treated mineral oils.
able also change the wettability characteristics, which • Solvent refined paraffinic mineral oils.
change the quenching performance. • Solvent refined naphthenic mineral oils.
Base oils are generally divided into two groups: • Re-refined mineral oils.
naphthenic and paraffinic grades. Naphthenic oils NAPHTHENE • Reclaimed mineral oils.
have a high proportion of cyclic hydrocarbons. Figure 2: Comparison of the structures of Double hydro-treated mineral oils are those that
Naphthenic grades contain very low portions of paraffins and naphthenes. are treated with hydrogen to remove carbon-carbon
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 double bonds. These double bonds can occur in aromatics and in impure there are limited suppliers. Increased local recycling reduces the supply
paraffinic oil. Because these double bonds are removed, they have greater and availability of feed stock. Since demand is high, presently re-refined
thermal and oxidative stability. They have a higher flash temperature, base oils are generally more expensive than virgin oils.
compared to other grades, and have a marginal improvement in the Some very low cost quench oils use reclaimed oils. Reclaimed oils are oils
cooling curve for the same viscosity. These oils are generally clear to that are recovered from many sources, including coolants, motor oils, and
a very light amber. However, the color is not indicative of staining greases. They are filtered and blended to give a specific viscosity. They may
tendency — that is the function of the additive package. The primary have an additive package thrown in to increase life. The primary advantage
disadvantage of double hydro-treated oils is availability and cost. is that they are cheap. Because the source of the oil is unknown, the presence
The refined paraffinic oils are the most commonly used base oil in of heavy metals and other products can be a disposal nightmare. It is not
quenchants. Besides the advantages cited earlier, they also have a wide unknown that transformer oils contaminated with PCB (polychlorinated
range of viscosities available (70-2500SUS). They are hydrophobic, which biphenyls) have been used. This poses a risk to the operator, but it’s also
means they displace water. This means better washing for the heat treater, a very expensive clean-up and disposal. Typically, viscosity is the only
and better splitting for improved reclamation. requirement, and multiple grades of motor oil greases, etc. are used to
Refined naphthenic base oils are readily available in a wide range of satisfy the viscosity requirement. These oils tend to have a poor life because
viscosities. Their primary advantage is cost. However, the reduced thermal the precursors to oxidation are already present as free radicals. Overall the
stability, lower flash temperatures and quicker thermal degradation tend to process cost is increased when these oils are used. More thorough cleaning
offset the advantages of cost. These oils are hydrophilic, which means that is required, with increased staining. Because a greater percentage of heavy
they tend to form emulsions. This means that the oils do not split well in stock is used, these oils tend to have higher drag-out and reduced life.
the washer, making recovery difficult. These oils also have a tendency to
absorb water. It is also difficult to drive water from these grades. CONCLUSIONS
Re-refined paraffinic base oils are oils recovered and passed through In this column the different types of quench oil were described, and
a cracker and distillation column. Specific viscosities with a very narrow the constituents in commercially available quench oil examined.
range are obtained from defined heights of the distillation column. These
oils have all the advantages of paraffinic base oils, with an additional REFERENCES
advantage of reduced light and heavy ends. This contributes to very Handbook of Quenching and Quenchants, G Totten, C. Bates and N.
stable and predictable response. The available viscosities are limited, and Clinton, editors, Metals Park, OH: ASM International, 1993.

ABOUT THE AUTHOR: D. Scott MacKenzie, Ph.D., FAS, is senior research scientist-metallurgy at Houghton International Inc. He is also President of
the International Federation of Heat Treatment and Surface Engineering (IFHTSE). Go online to www.houghtonintl.com.

sales@nordex.com | eng@nordex.com | (203) 775-4877

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ISO Certified / ITAR Registered / Trace Certified Release
03/2017

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GearSol_KISSsoft_Rel_03_2017_Highlights_92_25x123_83mm.indd 1 30.03.2017 13:35:56

GS February 2018.indb 25 1/23/18 12:18 PM

 COMPANY
PROFILE

TRUMPF GmbH Co. KG

Laser welding has been an innovative

and cutting edge solution for automotive
components. (Courtesy: TRUMPF)
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 TRUMPF may have started as a machine tool company,
but laser manufacturing has made it a shining industrial star.

By Kenneth Carter
Editor | Gear Solutions
TRUMPF has been manufacturing for nearly a century
but lasers energized the company’s mission, changing
it forever.
“In the late ’70s, we made one of the most impor-
tant decisions in our company’s history, which was to
develop laser technology,” said Ralf Kimmel, general
manager and head of the Laser Technology division at
TRUMPF Inc. “Cutting 2D sheet metal was not easy.
At that time, it was only done with punching tools.
However, we soon realized the potential that lasers
had for cutting sheet metal, and in 1985, TRUMPF
launched its first CO2 laser. This epiphany would
dramatically change the company in a positive way,
and now we have a second business division dedicated
solely to laser technology.”
Currently TRUMPF is one of the largest laser manu-
facturers in the world with annual revenue of about 3.1
billion euros, according to Kimmel.
BrightLine Weld allows for virtually spatter-free welding processes
“We have approximately 12,000 employees and about
during deep penetration welding. (Courtesy: TRUMPF)
60 subsidiaries all over the world,” he said.

LASERS LEAD TO GEARS cannot be measured directly within the production envi-
It was TRUMPF’s advancement in laser technology that ronment, the process is controlled indirectly with highly
bolstered the company’s offerings for gear manufactur- accurate positioning of the laser spot that’s relative to the
ing applications. weld joint with a real-time sensor-system. The challenge
“Laser welding creates a lot of advantages in gear man- is a very precise positioning of the laser beam and having
ufacturing,” Kimmel said. “We are able to weld high- a very small process window. But with this solution, the
carbonized material using lasers, so it offers additional availability of the process stays at a high level by doubling
joining capabilities. Using laser technology, TRUMPF productivity and creating higher parts quality.
entered the gear industry with powertrain welding. It
contains a lot of applications, and it is an important TRUMPF BRIGHTLINE WELD
market for the Laser Technology division.” But TRUMPF never settles. The company continues to
TRUMPF was the first company to use the technology develop innovative technologies that will help custom-
to weld differential gears without filler wire by the 1.5% ers get the most from their equipment, according to
C-effect, he said. Kimmel.
“The differential gear has a cast part made out of Brightline Weld, a welding technology developed and
high carbon content, and it needs to be joined with the patented by TRUMPF, allows a user to weld metals at
ring gear that’s made of case-hardened steel,” Kimmel double the speed or at double the welding depth.
said. “Typically, these two parts can’t be welded together “This is possible because of the new beam shaping,”
without filler wire. The use of the filler wire increases Kimmel said. “Beam shaping needs some special equip-
the complexity in production and needs permanent ment, but not a lot. We are creating a different optical
maintenance. The traditional way to put together a dif- setup for BrightLine Weld, which achieves higher speeds
ferential gear was through bolting the pieces together. with less power. These changes result in better productiv-
However, our R&D team developed a process where ity and lower costs.”
high-carbonized steel can be welded without filler wire, TRUMPF also offers laser marking and surface treat-
and this increases productivity and makes machines ment as additional applications.
easier to handle.” “Today, every gear has to be marked with an indi-
The high carbon content contribution of the cast iron vidual code,” Kimmel said. “This can be done with laser
normally leads to hardness cracking within the weld marking systems, which we offer as well. Many welding
seam, according to Kimmel. At a defined melt-pool operations require a cleaning process before joining and
mixture (resulting carbon mixture 1.5 percent), hardness welding, and this can be done with processes developed
values drop below 400 HV. Since the melt-pool mixture by TRUMPF.”
FEBRUARY 2018 27

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 TRUMPF’s TruMark is used to engrave identification numbers on a cog wheel. (Courtesy: TRUMPF)

TURNKEY AND OEM SUPPLIER

Kimmel said TRUMPF can operate as a turnkey supplier, delivering
products such as machine laser guidance optics, clamping devices,
quality measurement, and even automation.
“We don’t do this for all the applications,” he said. “A dif-
ferential gear is a typical project where we have all the neces-
sary handling devices and system requirements, but there are
some applications where our machine solutions do not fit the
requirements.”
The company can also operate as an OEM supplier for other machine
integrators. TRUMPF will deliver laser sources, beam guidance, fiber
optics, or central systems. An integrating company then completes the
handling and automation, according to Kimmel.
A big part of TRUMPF’s philosophy is making sure the buyer
knows how to get the product to perform perfectly for them.
“We have a philosophy at TRUMPF where we expect every-
thing related to our equipment to operate well — we call this
horizontal integration,” Kimmel said. “We don’t simply sell a
product to an integrator and then move on. We work with the
integrators to ensure our products deliver the consistent and
quality results our brand is associated with that customers Laser cleaned crown gear. (Courtesy: TRUMPF)

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 “Laser welding creates a lot of advantages in gear
manufacturing. We are able to weld high-carbonized
material using lasers, so it offers additional joining
capabilities. Using laser technology, TRUMPF entered the
gear industry with powertrain welding. It contains a lot of
applications, and it is an important market for the Laser
Technology division.”

expect. We try to understand the integra- system solution. After having this in place, we
tor’s processes. This dedication to excel- take over project management as a standout
lence is what separates us from others in service for our customers: manufacturing,
the industry. Proper horizontal integra- assembly, delivery, and onsite application
tion of our key technologies requires that support for startup and production.”
we deliver what the customer expects at
the end, every time. Customers don’t care THE FUTURE
about the beam quality of a laser or how As TRUMPF nears the century mark (it
a welding optic really works. They want was founded in 1923), it will continue
a specific part to be integrated into their to focus on lasers, beam guidance, and
systems, and then they want to achieve optics, where there is constant ongoing
a specific productivity level and quality development.
requirement. If the quality and produc- “About 70 percent of our products are
tivity is what the customer expects, he newer than two years,” Kimmel said.
or she shouldn’t care about the details “This gives you an indication of how
of how to do that.” much innovation is in the laser industry.
The most important development is that
WORKING WITH CUSTOMERS new central technologies are entering the
Kimmel said providing the right fit for market. Central technologies are so fast
a customer starts with understanding the and accurate that it is possible to look
application. online at the welding process and into the
“As an example, principle laser welding or keyhole to control your welding depth,
marking assessments are always the first step which is fantastic.”
in developing a project with a customer,” he Kimmel said he expects TRUMPF to
said. “We have highly skilled application make headways into new powertrain manu-
engineers in our own laser labs who take facturing applications.
sample parts. We have equipment for vari- “For example, electric cars are challeng-
ous processes like gear joining, welding, and ing all the powertrain manufacturers with
marking. Then we do fundamental tests on new requirements for gears and transmis-
sample parts for all the customers.” sions,” he said.
After understanding the application and Connectivity, or condition-based ser-
the production requirements that are set by vices, will rely on new capabilities to
the customer, TRUMPF specifies certain connect to a machine with software tools
elements such as productivity, part count, designed to evaluate massive amounts of
and automation levels. Based on this specifi- data, allowing for better control of pro-
cation, the next step is to develop the proper duction units, performing constant online
system, according to Kimmel. analysis of machines and recognizing fail-
“Then you have various options,” he said. ures before the machine fails, according
“The customer may want to bring in a spe- to Kimmel.
cific integrator, turnkey supplier, or auto- Kimmel eyes the future optimistically.
mation company. We often do a three- or “This is a very important new business
four-party development of the project. We field, which offers a lot of opportunities, and
cooperate with the automation deliverer, and TRUMPF is developing a lot of products,”
we are developing, step-by-step, the right he said. 

FOR MORE INFORMATION www.trumpf.com

FEBRUARY  2018 29

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GS February 2018.indb 30 1/23/18 12:18 PM
 An Examination of
High-Conformal Gearing
This paper describes the differences between Novikov gearing and Wildhaber
gearing, making a case for why the two systems should not be combined
as ‘W-N gearing.’
By Stephen P. Radzevich, M.S., Ph.D., Dr. (Eng.) Sci.

A brief historical overview on “Novikov gearing” is 1. HISTORICAL OVERVIEW

presented in this paper. It is shown that Novikov gear- Transmission and transformation of motion is the
ing is a reduced case of involute gearing. The concept main purpose of gearing of all kinds. The axes of rota-
of the “boundary Novikov circle” (identified by this tion of the driving and the driven gears can be arbitrarily
author, and referred to as the “N – circle” for simplicity) oriented in relation to one another. From this perspective,
enables a clear analysis of the geometry and kinematics three kinds of gearing are commonly distinguished:
of Novikov gearing. Necessary and sufficient conditions • parallel-axes gearing (or Pa – gearing, for simplicity),
for perfect operation of the conformal gearing (that is, • intersected-axes gearing (or Ia – gearing), and
Novikov gearing) and “high-conformal gearing” are • crossed-axes gearing (or Ca – gearing).
outlined. Use of the concept of “reversibly-enveloping For simplicity, but without loss of generality, the con-
surfaces” (or just “Re –surfaces”, for simplicity) makes sideration below is limited only to Pa – gearing.
it possible to state that gears neither Novikov gear- In the past, pin gearing, as well as other primitive
ing nor (more generally) for “high- kinds of gearing, were in use. None
conformal gearing” can be finish- of them is capable of transmitting a
machined in continuously index- rotation smoothly. Swiss mathema-
ing machining process; that is, the tician and mechanician Leonhard
gears cannot be finish-cut by hobs, Euler2 proposed involute gearing —
by shapers and rack-cutters, or by the only kind of Pa – gearing that is
worm grinding wheel, and so forth. capable of transmitting smoothly a
steady rotation from a driving shaft
INTRODUCTION to a driven shaft. Gearing of no
Invented at the beginning of 1950, other kind is capable of doing that.
Novikov gearing has been exten- The required equality of the base pitch-
sively investigated by many scien- es can be observed in involute gearing
tists and engineers. There is a large only and not in other gear systems.
body of published scientific work In external involute Pa – gearing,
on Novikov gearing available in the a convex involute tooth profile of the
public domain. The gearing is suc- driving member contacts a convex
cessfully used in helicopter trans- involute tooth profile of the driven
missions1 (Figure 1) [1], [2], as well member. In other words, external
as other applications. Figure 1: Novikov gear pair for helicopter involute Pa – gearing features “con-
Unfortunately, even to date transmission (Westland Helicopters, Ltd.). vex-to-convex contact” of the mat-
the kinematics and geometry of ing tooth profiles. As the contacting
Novikov gearing is not understood by most gear experts tooth profiles are convex, this imposes a strong limitation
around the world. Many scientists and researchers in the on the bearing capacity of the involute gearing because
field of gearing still loosely refer to Novikov gearing as of high contact stress in “convex-to-convex contact”. It
to “Wildhaber-Novikov gearing,” or just to “W-N gear- is highly desired to replace two convex contacting tooth
ing.” This indicates insufficient training in the theory profiles of the gear teeth with their “convex-to-concave
of gearing, especially the absence of understanding the contact.” In conventional involute gearing this is not
kinematics and geometry of both, of Novikov gearing, permissible, as it inevitably entails the violation of three
Fig. 1. Novikov gear pair for helicopter transmission (Westland Helicopters, Ltd.).
and “Wildhaber gearing” as well. In this paper, the dif- fundamental laws of gearing [3].
ference between two gear systems is clearly outlined. It The breakthrough invention in the realm of gearing
is shown that Novikov gearing and Wildhaber gearing has been made in 1950. As early as 19563, a novel gearing
must be considered only separately, and it is a mistake was proposed by Dr. M. Novikov [4]. The concept of the
combining two gear systems in a common system (that is, proposed gear system is illustrated in Figure 2 [4]. Later
to “W-N gearing”). Potential improvements to Novikov on, Novikov gearing was investigated in his doctoral
gearing are disclosed. thesis [5] and are summarized in the monograph [6].
FEBRUARY 2018 31

GS February 2018.indb 31 1/23/18 12:18 PM

 t

Boundary Novikov circle

db. p

rN
C
L
ωp
Op P
LAinst
Vlc b
C
a
Figure 2: On the concept of Novikov gearing (after
Dr. M. Novikov; USSR Pat. No. 109,113, 1956) the
“boundary Novikov circle” of a radius, rN , is b
introduced later by Dr. S.P. Radzevich.
Plane of action
b
Below, we do not follow the approach LCdes
used by Novikov to design a gear pair
G
Fig. 2. On the concept of “Novikov gearing” (after Dr. M. Novikov; USSR Pat. No. 109,113, 1956 (the “boundary
of novel design. Instead, the concept of
Novikov circle” of a radius, r N , is introduced later on by Dr. S.P. Radzevich.
Novikov gearing is derived on the basis ωg
of conventional external parallel-axes
involute gearing. Gearing of this kind Og
is chosen for the derivation, as in nature db.g
Novikov gearing is a reduced case of
involute gearing 2 .

2. PRINCIPAL DESIGN FEATURES Figure 3: The kinematics of parallel-axes gearing.

OF NOVIKOV GEARING
For the designing a pair of Novikov
gearing, let’s assume that a location and the equality Σ˜=˜0º is valid. db.p˜=˜2rp cos˜φ˜ EQUATION 2
orientation of the axes of rotation of the The principle of inversion of rotations
driving, and driven members of the gear can be implemented to the gear pair to be Once the base cylinders are determined,
pair to be designed is specified, and the designed. Let’s assume that both the axes then transmission of a rotation from the
gear ratio is given. The desired value of of the rotations, Og and Op, are rotated driving member to the driven member of
the transverse pressure angle is also known. together with the rotation vector, –ωg. the gear pair can be interpreted with the
With that said, a pair of Novikov gears can Because the identity ωg˜ +˜ (–ωp)˜ ≡˜ 0 is help of the so-called “pulley-and-belt anal-
be designed following the routine briefly valid, the gear becomes stationary under ogy” (Figure 3).
outlined below. the additional rotation, –ωg. The pinion is Either equation (1) or (2) can be used for
2.1. Vector diagram of a gear pair. rotated with the rotation: ωpl˜=˜(ωp˜–˜ωg). the derivation of an expression for the cal-
Designing a pair of Novikov gears begins The vector of instant rotation, ωpl , of the culation of the base pitch, pb, in a transverse
with the construction of the vector dia- pinion in relation to the gear is along the section of the gear pair:
gram of the gear pair to be designed. The axis of instant rotation, Pln. More in detail
rotation vector4 of the gear, ωg, is along the vector diagrams Fig.
are3. The kinematics
discussed in [3]. ofPb˜=˜°
parallel-axes
db.g˜/˜Ng˜=˜° dgearing.
b.p˜/˜Np EQUATION 3
the axis of rotation, Og, of the gear. The 2.2. Plane of action in parallel-axes gear-
magnitude, ωg, of the rotation vector, ωg, ing. The plane of action, PA, in parallel-axes Equation˜ (3) is valid for Pa˜ –˜ gearing
equals to ωg˜=˜| ωg |. The rotation vector of gearing is a plane through the axis of instant that is capable of transmitting a rotation
the mating pinion, ωp, is along the axis of rotation, Pln . This plane forms a transverse smoothly.
rotation, Op, of the pinion. The magnitude, pressure angle, φt, with the perpendicular 2.3. A desired line of contact in parallel-
ωp, of the rotation vector, ωp, is ωp˜=˜| ωp |. to the plane through the axes of rotation, axes gearing. The tooth flank of the gear,
The magnitudes, ωg and ωp, relate to one Og and Op, of the gear and of the pinion G , and that of the pinion, P , make con-
another as: u˜=˜ωp / ωg. respectively. The base diameter of the gear, tact along a desired line of contact, LCdes
The axes of rotation, Og and Op, are at db.g, and that of the pinion, db.p, can be (Figure 3) or just a line of contact, LC. The
a certain center-distance, C. The rotation expressed in terms of the pitch radii, rg and line of contact, LC, is a planar curve of a
vectors, ωg and ωp, form a crossed-axes rp, of the pitch cylinders, and the transverse favorable geometry that is entirely located
angle, Σ, that is: Σ˜=˜∠(ωg ;˜ωp). In a case of pressure angle, φt : within the plane of action, PA. The teeth
external Pa˜–˜gearing, the angle, Σ, always flanks, G and P of the gear and the mat-
equals Σ˜= Σ 180º; in internal Pa˜–˜gearing db.g˜=˜2rg cos˜φt EQUATION 1 ing pinion interact only within the active
32 gearsolutions.com

11.Feat1-Gear inpsect-2018-02 v2.indd 32 1/23/18 3:32 PM

 Sourcing Mad
portion of the plane of action, as is shown gear designer when selecting the geom- portion of the involute tooth profile shrinks
in Figure 4. etry of non-active portions, ac and bd, to point, K. This point is referred to as the
Referred to Figure 4a, the straight-line of the tooth profile. As these portions of “involute tooth point.” The non-active por-
segment, N g N p , is the total length of the tooth profile do not interact with one tions, aK and bK, of the tooth profile meet
the plane of action. In reality, the active another, the geometry of the segments, ac each other at point, K. These portions are
portion of the plane of action, PA, is of a and bd, is not restricted by the conditions not subject to conditions of meshing of tooth
shorter length, Z pa (Figure 4b). In a case of meshing of the tooth profiles (which is profiles, thus this gives a certain freedom to
of Novikov gearing, the equality, Z pa˜=˜0, the must for the active portion, cd ). the gear designer when selecting the geom-
is observed. In the extreme case, the EAP˜–˜circles of etry of non-active portions, aK and bK, of
In involute helical Pa˜ –˜ gearing, the the gear and of the pinion can pass through the tooth profile (Figure 4d).
desired line of contact, LC, between the a certain point K within the straight-line As the length of the active portion of the
tooth flank of the gear G and the pinion P segment, PgPp. Because of this, the length, plane of action is zero (Zpa˜=˜0), and the
(remember, that the tooth flanks, G and P Zpa, of the active portion of the plane of involute tooth profile is shrunk to point,
, are not constructed yet) is a straight-line action becomes zero (Zpa˜=˜0), and the active the transverse contact ratio, mp, results in a
segment that forms a base helix angle, Ψb,
with the axis of instant rotation, Pln .
The total contact ratio, m t , can be
expressed in terms of the transverse contact
ratio, mp, and the face contact ratio, mF : Sourcing Made Simple
mt˜=˜mp˜+˜mF EQUATION 4

where: mp˜=˜Zpa˜/pb and mF˜=˜Fpa tanΨb /pb.

The inequality, mt °˜0, must be observed
for any and all parallel-axes gear pairs.
When the base cylinders of diameters, Trusted Gear Blank
Supplier Since 1950 Truste
d b.g and d b.p, rotate, the desired line of con-
tact, LC, travels (together with the plane
of action, PA) in relation to the reference
systems, one of which is associated with
the gear and another associated with the
S
pinion. In such a motion, the tooth flank
of the gear, G (as well as the tooth flank Consistent Quality Consi
of the pinion, P ) can be interpreted as
a family of consecutive positions of the Broad Capability & Capacity Broad
desired line of contact in the correspond-
ing reference system. Exceptional People Excep
In the example (Figure 4b), the active Trusted Gear Blank On-tim
portion, ab, of the gear tooth profile5 is
shaped in the form of an involute of a circle.
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the outer cylinders of the gear and of the Broad Capability & Capacity
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For both members of a gear pair — that
is, for the gear and the pinion — the radi-
us, r eap, of the EAP˜–˜circle can be smaller
than the outer radius of the gear, r o.g (or
than the outer radius of the pinion, ro.p , for
example) due to chamfering. Under such walkerforge.com
walkerforge.com | 414.223.2000 414.223.2000|
a scenario (Figure 4c), the active portion
of the plane of action gets narrower. The
SAP˜–˜point c, and the EAP˜–˜point d
become closer to one another: The active
| 414.223.2000
portion, cd, of the involute tooth profile is
shorter than that, ab, illustrated in Figure
4b. This gives a certain freedom to the
FEBRUARY 2018 33

11.Feat1-Gear inpsect-2018-02 v2.indd 33 1/23/18 3:33 PM

 Y Vg. K
do. p
p Vsl
p
do.g
Op

p rf . p Vpa
Op rp C
rp.K Vp.K
P Ng
db. p X
Np K Pg Pp
C
L
ro. p t rg.K db.g
rb. p

Pg P Pp Ng rN t g Og

Np K
g
PA r f .g rb.g
rg Figure 5: Tooth profile sliding in parallel-axes Novikov gearing.
(a )
g
ro.g For this case, Novikov proposed to replace
“convex-to-convex contact” of the teeth
C sin t Og profiles in involute gearing with their
“convex-to-concave contact”gearing”. in Novikov
pt Fig. 5. Tooth profile sliding in parallel-axes “Novikov

b gearing. The replacement only becomes

possible in a case when the active portion
PA of the involute tooth profile is shrunk to
LC
(b) Z pa Fpa point (and it is infeasible in cases when the
px active portion of the involute tooth profile
a is of a certain length [3]).
Shown in Figure 2, the first (in time)
b schematic that illustrates the concept of
b Novikov gearing [4] is far from being the
Z pa d best and most consistent.
Point of contact, K, of the tooth f lanks,
(c) Fpa G and P , is located within the straight
PA c
LC line of action, LA. The larger the distance
a of the contact point, K, from the pitch
point, P, the more freedom is there for
b the gear designer in selecting the radii of
b
Z pa = 0 curvature of the interacting tooth profiles.
K d
Pc VK At the same time, the larger the distance
(d ) Fpa of the contact point, K, from the pitch
K
Vpc c point, P, the higher losses on friction
Ppc
a between the tooth f lanks, G and P , and
l the higher the tooth f lanks wear (Figure
l pc ≡ 0 5). Ultimately, the actual location of the
contact point, K, is a tradeoff between the
Z pa ≡ 0 two factors just mentioned.
Further, let’s assume that the pinion
Fig. 4. (Replacement).
is stationary, and the gear performs an
b instant rotation in relation to the pinion.
The axis, Pln , of the instant rotation, ωpl,
Figure 4: Elements of a parallel-axes gear pair featuring zero transverse contact ratio (mp = 0). is a straight line through the pitch point,
P. When the pinion is motionless, the con-
zero value. In order to meet the inequality, non-active portions of tooth profiles of tact point, K, traces a boundary Novikov
mt ≥ 0, the following inequality must be met: the gear and the pinion as the geometry circle 6 of a radius, r N, that is centered at
of these portions is free of constraints P, as illustrated in Figure 2.
mt = mp + mF = 0 + mF = mF  > 0 imposed by conditions of the meshing of The pinion tooth profile, P , can either
EQUATION 5 two conjugate tooth profiles. align with a circular-arc of the boundary
2.4. Design features of Novikov gearing. Novikov circle of a radius, r N, or it can be
The point system of Pa – gearing (Figure The concept of Novikov gearing is based relieved in the bodily side of the pinion
4d) gives much freedom when designing on the schematic depicted in Figure 4d. tooth. The pitch point is included into
34 gearsolutions.com

GS February 2018.indb 34 1/23/18 12:18 PM

 the interval, while the contact point, K, is length (P c ≡ 0), and that the point of con- of a gear and a mating pinion becomes
not. From the other hand, the location of tact pseudo-travels axially across the full feasible is the fundamental achievement
the center of curvature of the concave gear face width of the gears during rotation. by Novikov. Once the active tooth pro-
tooth profile, G , within the straight line, The pseudo-travel distance is equal to files in a parallel-axes involute gearing
LA, is limited to the open interval P ➞ ∞. Ppc = F pa . It should be stated as a condi- shrunk to a point (that is, to the “involute
Theoretically, the pitch point, P, can be tion of the operation of Novikov gearing tooth point”), then a favorable contact
included in this interval for K. The radius that, for a given profile, the tooth surfaces between the tooth f lanks, G and P , can
of curvature, r p, of the convex the pinion should not interact before or after culmi- be attained. A capability to accommodate
tooth profile, P , is smaller than that, r g, nation when rotated at angular speeds that for the manufacturing errors and for the
of the concave the gear tooth profile, G. are in the gear ratio. displacements under an operating load is
Thus, the inequality r p < r g is observed7. The transverses contact ratio, m p in the only consideration when determin-
In Novikov gearing, both the pinion, and Novikov gearing is zero, (mp = 0). Because ing the geometry of the interacting tooth
the gear are helical. The helices are of the of this, geometrically, the meshing of the profiles, G and P, by Novikov.
opposite hand. No spur Novikov gearing is gear teeth in transverse section is instant. 3.1. A critical degree of conformity in
feasible at all. Due to that, when the gears The face contact ratio, m F, of the gear pair Novikov gearing. It was assumed from the
rotate, contact point, K, “pseudo-travels” is always greater than one (m F = mt > 1). very beginning that convex-to-concave
axially parallel to the axis of instant rota- 2.5. Principal design parameters of contact between the tooth flanks of a gear
tion, Ppl . In this straight “pseudo-motion,” Novikov gearing. From a historical perspec- and a mating pinion is sufficient for a sig-
the contact point traces a straight line, Ppc, tive, it is interesting to consider the calcula- nificant increase of bearing capacity of the
that is called the “pseudo-path of contact, tion of the principal design parameters of a contact area between the tooth flanks, G
Ppc ” [as the equality Zpa = 0 is observed, the Novikov gear pair following the approach and P. The analysis reveals that in case of
length of the path of contact, Pc, at every proposed by Novikov [6]. In current ter- Novikov gearing, convex-to-concave con-
transverse section is always zero (Pc ≡ 0)]. minology and designations, the calcula- tact is necessary, but not sufficient for a
The radial position of the contact point, tion of the principal design parameters of significant increase of power capacity of
K, on both the gear and pinion teeth a Novikov gear pair is considered in [3]. Pa –  gearing. A certain critical degree of
f lanks, G and P , remains the same. It is, conformity at point of contact, K, of the
therefore, fundamental to the operation 3. HIGH-CONFORMAL GEARING tooth flanks, G and P , must be attained in
of the gears that contact occurs nominally Conditions under which “convex-to-con- order to make the convex-to-concave con-
at a point, the path of contact is of a zero cave contact” between the tooth f lanks tact beneficial. An increase in the degree of

FEBRUARY 2018 35

GS February 2018.indb 35 1/23/18 12:18 PM

 t

rb.g
cnf = cnf ( k , K )
cnf t LAinst

Ki = Const
rb.g
LAinst
P
ki = Const

k
Og
P a
K rN
Og
Figure 6: Three-dimensional plot of the function,
( X ,δ
Y , Z) = δ
cnf cnf (k,K), constructed for “convex-to- G
a
concave” kind of contact between the tooth flanks of a rN K
gear, G, and a mating pinion, P, in a “conformal” gear b ng
pair.

conformity under its critical value — that (a) G

is, from δacnf to δbcnf  — makes possible a b K
limited
Fig. 6. Three-dimensional increase
plot of the function, of
cnf the
= cnf bearing capacity
(k , K ) , constructed for “convexof
–to–concave” kind of ng
the gear pair. A low increase of the bear-
contact between the tooth flanks of a gear, G , and a mating pinion, P , in a “conformal” gear pair.
≡0
ing capacity is because of both the values
of degree of conformity (that is, δacnf and
δbcnf ) are smaller the critical its value [δcnf ],
and thus the inequalities δacnf < [δcnf ] and (a) ≡0
δbcnf < [δcnf ] are observed.
However, when the actual degree of
conformity, δccnf, becomes larger than the
critical value (δccnf  >  [δc nf ]), then even a
(a)
small increase in degree of conformity at t
the point of contact of the tooth flanks,
G and P, causes a significant increase in rb.g
bearing capacity of the tooth flanks in
Novikov gearing. Therefore, the substitu-
t LAinst
tion of convex-to-convex contact between
the tooth flanks in Pa – gearing with their rb.g
convex-to-concave contact (as in Novikov
gearing) is necessary, but not sufficient for LAinst
a significant increase in power capacity of P
a parallel-axes gear pair. In addition to
Og rg
that, a certain critical degree of confor-
og c
mity, [δc nf ], at point of contact between P a
the tooth flanks of the gear, G and of the (b)
pinion P , must be exceeded. Og rg
Gearing for which degree of confor- og b c
G
mity, δc nf, at point of contact of the tooth a
f lanks, G and P, is larger than its criti- Figure 7: Correct, G (a), and incorrect, G* (b) K n*g
cal value, [δc nf ] — that is, the gearing configurations of the circular-arc tooth profile
for which the inequality, δc nf  >  [δc ], is of a gear in Novikov gearing (the common
perpendicular, n , is aligned with the instant bd G * G
observed — is referred to as the “high- line of action, LA g ) and in “Wildgaber
conformal gearing.”
inst
gearing” (the common perpendicular, ng , does
K n*g
The intuitively understood qualitative not align with the instant line of action, LA inst ).
term “degree of conformity” can be quan- d G *
tified. For this purpose, a characteristic
curve called the “indicatrix of conformity,
CnfR  (G  /P  )”, at the point of contact of fourth order. Position vector of a point, [7]. The smaller the radius, r cnf, the larger
the tooth flanks of a gear, G, and a mating rcnf, of the indicatrix of conformity cor- the(b ) of conformity at point of con-
degree
pinion, P , is commonly used [3], [7]. The responds to degree of conformity of the tact of the surfaces, and vice versa.
indicatrix of conformity, CnfR (G /P ), is tooth flanks, G and P, in a corresponding 3.2. A minimum required degree of con-
a planar centro-symmetrical curve of the direction through the contact point K [3], (b) at the point of contact the interacting
formity
36 gearsolutions.com
Fig. 7. Correct, G (a), and incorrect, G * (b) configurations of the circular-arc tooth profile of a gear in“No
GS February 2018.indb 36
gearing” (the common perpendicular, n g , is aligned with the instant line of action, LA ), a
1/23/18 12:18 PM inst
 tooth flanks. Favorable conditions of con- various forms of surface failure such as Figure 6 in bold line, the axis, δcnf, and the
tact of the tooth flanks of the gear and the heavy wear, pitting or scuffing damage. straight line, δcnf˜=˜1, are the asymptotes.
pinion is the main anticipated advantage of Therefore, a minimum required degree of The greatest possible degree of mis-
a high-conformal gear pair. The higher the mismatch in the curvature of the teeth of match in the curvature of the teeth of gear
degree of conformity, the higher the load- gear and pinion is necessary to be deter- and pinion corresponds to the parameter,
–
carrying capacity of the contacting tooth mined. Otherwise, one of two scenarios K ➞˜° . The interval of alteration to the
–
f lanks. Therefore, a minimum possible could be observed. First, the gear pair is parameter, K, starting from –° and going
–
mismatch in the curvature of the teeth of capable of absorbing the inevitable dis- up to approximately, K˜=˜–2, is convenient
gear and pinion is desired. placements of the tooth flanks, but the to accommodate for any desired displace-
In reality, tooth f lanks of a gear and a degree of conforming of the contacting ment of the tooth f lanks, G and P , from
mating pinion in a high-conformal gear tooth flanks is not sufficient for high load- their correct configuration. However,
–
pair are displaced from their desired posi- carrying capacity of the gear pair. Second, within the interval (–° ˜ <˜ K˜ <˜ –2) of
–
tion. The undesired displacements are the gear pair features sufficient degree of alteration in K–˜parameter, an increase of
mostly because of: (a) the manufactur- conformity of the tooth flanks, but is not the degree of conforming of the tooth pro-
ing errors, and (b) the elastic def lec- capable of accommodating for the tooth files, G and P, is negligibly small. Within
–
tions of the gear teeth, of the gear shafts, flank displacements. In both cases, the this interval of K–˜parameter, the load-
of the housing that is occurred under gear pair has no chance being successfully carrying capacity of a conformal gear pair
the applied load, thermal expansions of used in practice. is remained approximately at the same
the components, and so forth. High- Shown in Figure 6 is a 3D plot of the range. Therefore, just convex-to-concave
–
conformal gearing is sensitive towards the function δcnf˜=˜δcnf (k, K). Figure˜6 relates contact between the tooth f lanks of a
tooth f lanks displacements. to the cases of convex-to-concave contact gear and a mating pinion gives a lim-
To accommodate for the inevitable dis- of tooth flanks of the gear, G, and the ited improvement in the load-carrying
placements, a certain degree of mismatch pinion, P. capacity of a gear pair. Being convex-
in the curvature of the teeth of gear and The performed analysis of the 3D plots to-concave, an additional requirement
pinion is required. A small mismatch can allows for the following conclusions. needs to be satisfied in order to get not
be incapable of accommodating the dis- The sections of the surface, δcnf˜=˜δcnf (k, just conformal gearing, but instead to get
–
placements. However, as the mismatch K), by planes ki˜=˜Const (Figure 6) are rep- high-conformal gearing.
increases, the contact stresses increase resented with curves that have asymptotes. On the other hand, even small change
–
as well. High contact stress may lead to For a particular curve, ki˜=˜Const, shown in to value of the K–˜parameter within the

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FEBRUARY 2018 37

11.Feat1-Gear inpsect-2018-02 v2.indd 37 1/23/18 12:33 PM

 –
interval (–2 < K < –1) results in significant
increase of the degree of conformity of the
Novikov gearing is not It is a mistake to refer to Novikov gear
system as to gears with a “circular-arc
teeth flanks, G and P. This immediately a kind of gearing with a tooth profile.” Novikov gearing is not a
entails a corresponding increase in load- kind of gearing with a circular-arc tooth
carrying capacity of the gear pair. circular-arc tooth profile profile like gears in a Wildhaber gear sys-
In the example considered above, the
– like gears in a Wildhaber tem. Novikov gearing is a reduced kind of
value of the K–  parameter (that is, the involute gearing. In Novikov gearing, the
–
value of K ≈ –2) can be referred to as its gear system. working involute tooth profile is shrunk
–
critical value, Kcr. This allows for distin- to a point. This point is referred to as the
guishing between just conformal gearing unit perpendicular, n g, is not aligned with “involute tooth point.” The rest of the
– –
(for which –∞ < K < Kcr) from high-con- the instant line of action, LA inst, as illus- tooth profile is inactive, and thus can be
– –
formal gearing (for which Kcr < K < –1). trated in Figure 7b. The gear tooth f lank, shaped with no constraints imposed by the
Without going into details of the analy- G* is improperly configured in relation three fundamental laws of gearing.
sis, it is clear that gears for high-confor- to the boundary N – circle in a gear pair. The acting standards on Novikov gear-
mal gearing require tighter tolerances for Helical gearing with circular-arc tooth ing (in Russia, China, and elsewhere), and
any possible displacements of the tooth profile proposed by Dr. E. Wildhaber [9] on gear cutting tools for cutting gears for
f lanks, G and P, from their desired loca- does not meet three fundamental laws Novikov gearing are generally incorrect.
tion and orientation. Otherwise, there of gearing. Insufficient understanding Gears for Novikov gearing cannot be cut
could be no future for application of of gearing of this particular kind clearly (finish-cut) by hobs, shaper cutters, shavers,
high-conformal gear system. follows from the paper by T. Allen [13]. worm grinding wheels, and others. No gen-
Based on the results of the performed The comparison of the Novikov gear- erating machining of gear teeth flanks are
analysis, the following statement is valid: ing [4] and the Wildhaber gearing [9], allowed. Only disk type mill-cutters, disk
conformal gearing and high-conformal gear- started decades ago by N. Chironis [10], form grinding wheels, and so forth, can be
ing meet all three fundamental laws of gear- is incomplete. To the best possible extent, used for this purpose.
ing [3], [7], [8]. They are capable of transmit- the comparison was later accomplished High-conformal gearing has a huge poten-
ting an input-steady rotation smoothly. As a in my own work as summarized in [3], tial for application in high-power-density
consequence, conformal gearing, as well as [8], [11]. transmissions, and in low-noise gear trans-
high-conformal gearing, feature: Two points need to be mentioned here. missions. 
• The transverse contact ratio is identical to First, neither gears for Novikov gearing,
zero (mp ≡ 0); nor gears for high-conformal gearing, REFERENCES
• The total contact ratio, mt, is equal to the can be finish-cut by continuously-index- 1. Shotter, B.A., “Experiences with
face contact ratio, mF, and is greater than ing method of gear machining. That is, C o n f o r m a l / W- N G e a r i n g ,”
one (mt = mF > 1); the gears cannot be hobbed, shaped, or Proceedings of World Congress on
• The tooth profile of one member of the ground by the worm grinding wheel. Gearing, Paris, France, June 22-June
gear pair is convex, while the tooth profile This is because three fundamental laws of 24, 1977, pp. 527-540.
of the mating gear is concave; gearing are not fulfilled in the gear machin- 2. Shotter, B.A., “The Lynx Transmission
• The convex tooth profile of one member of ing mesh [7]. Only Re – surfaces can be accu- and Conformal Gearing,” SAE Technical
the gear pair is entirely located within the rately generated in a continuously-indexing Paper 781041, 1978.
interior the boundary N – circle, while the method of gear machining. Cutting tools for 3. Radzevich, S.P., Theory of
concave tooth profile of another member machining gears for both — for Novikov Gearing:  Kinematics, Geometry, and
of the gear pair is entirely located within gearing as well as for high-conformal gear- Synthesis, CRC Press, Boca Raton
the exterior of the boundary N –circle; ing — are considered in [8] and [12]. Florida, 2012, 743 pages.
• The difference between the magnitudes Second, neither tooth profile nor longitu- 4. Pat. No. 109,113, (USSR). Gearing and
of radii of curvature of the concave tooth dinal modification of the tooth flanks of the Cam Mechanisms Having Point System
profile and the convex tooth profile in gear and the pinion is applicable to Novikov of Meshing, M.L. Novikov, National
the gear pair is equal to, or smaller the gearing, as well as to high-conformal gearing Classification 47h, 6; Filed: April 19,
given threshold beyond which higher con- in a more general case. 1956, published in Bull. of Inventions
formity of the interacting tooth profiles No.10, 1957.
contributes much to the bearing capacity CONCLUSION 5. Novikov, M.L., The Principles of the
of the gear pair. It is stressed in this paper that poor under- Geometric Theory of Point Meshing
The principal difference between standing of the kinematics and geometry of Gearing for the Purpose of
Novikov gearing and between Wildhaber of the novel kind of gearing proposed by Transmitting of High Power, Doctoral
gearing is clearly illustrated in Figure 7. Novikov is the root cause for loosely combi- Thesis, Moscow, Aviation Engineering
In Novikov gearing, the common unit nation of Novikov gearing with Wildhaber Academy bearing the name of Prof.
perpendicular, n g , is always aligned with gearing. These two types of gearing must be N.Ye. Zhukovskii, 1955.
the instant line of action, LA inst, as illus- considered only separately from one another. 6. Novikov, M.L., Gearing that is featur-
trated in Figure 7a. The gear tooth f lank, The terms “Wildhaber-Novikov gearing,” ing a Novel Kind of Meshing, Moscow,
G, is properly configured in relation to as well as “W-N gearing,” are incorrect, Published by Aviation Engineering
the boundary N – circle of a radius, r N . and must thus be eliminated from scientific Academy bearing the name of Prof.
In Wildhaber gearing, the common communication on gearing. N.Ye. Zhukovskii, 1958, 186 pages.
38 gearsolutions.com

GS February 2018.indb 38 1/23/18 12:18 PM

 7. Radzevich, S.P., Geometry of Surfaces: Science and Engineering, 2nd Edition, been machined in summer of 1954 by
A Practical Guide for Mechanical CRC Press, Boca Raton Florida, 2017, means of disk-type mill cutter.
Engineers, Wiley, 2013, 264 pages. 606 pages. [1st edition: Radzevich, S.P., 4. It should be stressed here that a rota-
8. Radzevich, S.P., High-Conformal Gear Cutting Tools: Fundamentals of tion in nature is not a vector at all.
Gearing: Kinematics and Geometry, Design and Computation, CRC  Press, However, if special care is undertaken,
CRC Press, Boca Raton, Florida, Boca Raton Florida, 2010, 786 pages.. rotations can be treated as vectors.
2015, 352p. 13. Allan, T., “Some Aspects of the Design 5. The tooth involute profile is called
9. Pat. No. 1,601,750, (USA). Helical and Performance of Wildhaber-Novikov “involute” because the active portion
Gearing. /E. Wildhaber, Filed: November Gearing,” Proc. Inst. Mech. Engrs, Part of the tooth profile is shaped in a form
2, 1923, published October 5, 1926. I, v. 179, n. 30, 1964/1965, pp. 931-954. of an involute of a circle, regardless of
10. Chironis, N., “New Tooth Shape the rest of the gear tooth profile (fil-
Taking Over? Design of Novikov ENDNOTES lets, bottom-lands) are not involute.
Gears”, pp.124-135 in: Gear Design 1. These gears in Westland Helicopters. 6. It is instructive to mention here that
and Application, Edited by Nicholas Ltd. were finish-cut by disk-grinding Dr. M. Novikov did not use the con-
Chironis, McGraw-Hill Book wheel. cept of the “boundary circle.” At the
Company, New York, 1967, 374p. 2. The proposed by L. Euler involute beginning of 2000s, the concept of
11. Radzevich, S.P., Dudley’s Handbook of gearing deserves to be called as “Euler the “boundary circle” was introduced
Practical Gear Design and Manufacture, gearing,” or just as “gearing,” for sim- by Dr. S. Radzevich [3]. He also pro-
3rd edition, CRC Press, Boca Raton plicity. posed to refer to this circle as to the
Florida, 2017, 606  pages. [Radzevich, 3. It should be mentioned here that the “boundary Novikov circle,” or just as
S.P., Dudley’s Handbook of Practical first pair of Novikov gears made out of to “N– circle” of a limiting radius, r N .
Gear Design and Manufacture, 2nd edi- an aluminum alloy (a pre-prototype) 7. It should be pointed out here that there
tion, CRC Press, Boca Raton Florida, had been cut on April 25, 1954 by are no constraints to design a gear pair
2012, 880 pages]. means of disk-type mill cutter. Fifteen with a convex gear tooth profile, and
12. Radzevich, S.P., Gear Cutting Tools: gear pairs for testing purposes had with a concave pinion tooth profile.

ABOUT THE AUTHOR  Stephen P. Radzevich, M.S., Ph.D., Dr. (Eng.) Sci., can be reached at 586-292-7209 or radzevich@usa.com.

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 40 gearsolutions.com

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 Induction Gear Hardening
Part 1: The practice and science of modern induction heat-treating has
advanced in many areas over the last decade, including computer modeling,
power supplies, failure analysis, quality assurance, and more.
By Dr. Valery Rudnev, FASM

Over the years, gear manufacturers have increased GEAR HEAT-TREAT RESOURCES
their knowledge of the production of quality gears and Gear heat-treating by means of electromagnetic induc-
gear-like components. This knowledge has led to many tion is a topic of major significance, and the technology
improvements including lower noise, lighter weight, and continues to grow. The second edition of the Handbook
lower cost as well as increased load-carrying capacity of Induction Heating (Figure 2) was recently published,
to handle higher speeds and torque with a minimum reflecting innovations that have taken place over the last
amount of generated heat. decade in the practice and science of modern induction
Improvement in wear resistance, contact fatigue heat-treating, computer modeling, power supplies, failure
strength, endurance and impact strength helps to elimi- analysis, quality assurance, etc. [1]. This includes:
nate premature gearbox failure. Formation of consider- • Subtleties of tooth-by-tooth induction hardening of
able compressive residual stresses at the surface and in the large gears. A comparison of inductor designs. Ways
subsurface help inhibit crack development to avoid back tempering. Control of elec-
and resist tensile bending fatigue. Gear tromagnetic end and edge effects.
performance characteristics dictate the • Gear spin hardening using encircling
required surface and core hardness, hard- coils. Effect of frequency and power on
ness profile, residual stress distribution, hardness pattern. Single frequency vs.
grade of steel, and its prior microstructure. simultaneous dual frequency vs. IFP-
In contrast to carburizing and nitrid- Technology. Achieving true contour hard-
ing, induction hardening does not require ening of gears and gear-like components.
heating the whole gear or pinion. Instead, • Metallurgical insights of induction
the heating can be primarily localized to hardening steels, cast irons, and powder
the areas where metallurgical changes are metallurgy components. Effect of rapid
desired [1]. Piece-by-piece processing capa- heating on the kinetics of austenite for-
bility with individual component trace- mation. Impact of steel cleanliness, prior
ability and environmental friendliness are Figure 2. Second edition of the microstructure, heterogeneity and pres-
two other features that make an induction Handbook of Induction heating ence of residuals and inclusions.
technology very attractive. Not all gears and is new technical resource • Subtleties of quenching techniques
for induction heat treat
pinions are well suited for induction harden- professionals. applied in induction hardening. Shape/
ing. External spur and helical gears, worm size distortion control and prevention of
gears, internal gears, racks, and sprockets are among those cracking. Transient and residual stresses.
that are typically induction hardened (Figure 1). • Specifics of hardening parts for automotive, aero-
Depending on the size of the gear, the required space, off-road and other industries. Innovations and
hardness pattern, and tooth geometry, gears are induc- inventions in equipment designs maximizing process
tion hardened by encircling the whole gear (external robustness and machine flexibility.
or internal) with an induction coil (the so-called • Simple solutions for typical induction heating challeng-
“spin hardening”) or, for larger gears, hardening them es. Best practices for equipment maintenance and safety
tooth-by-tooth with either gap-by-gap or tip-by-tip principles, “Do’s and Dont’s” items, and many others.
heat-treating techniques. This installment is the first of a two-part article focus-

Figure 1. External spur and helical gears, worm gears, internal gears, racks, and sprockets are among those that are typically induction
hardened.

FEBRUARY  2018 41

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 Figure 3. The tooth-by-tooth hardening and the path of the induced eddy current [1].

ing on material selection, metallurgical subtleties of rapid heating of induction hardening applications.
and specifics of tooth-by-tooth induction hardening of medium-size Rapid heating causes a measurable increase of critical temperatures
and large gears. Part II will be devoted to induction spin hardening (e.g., Ac1, and Ac3) compared to the corresponding temperatures A1
of small and medium-size gears. and A3 indicated by the equilibrium phase transformation diagram.
The nucleation and growth of austenite in the rapid heating of mea-
MATERIAL SELECTION surably heterogeneous initial structures are more concerning than in
Several guidelines, recommendations, and standards help to select an case of thermo-chemical diffusion processes (e.g., carburizing), which
appropriate material for gears, including AGMA, ANSI, and ASTM applies significantly longer process times. Selection of hardening
standards. Since induction hardening does not change the chemical temperatures based on the equilibrium Fe–Fe3C diagram and failure
composition of steel, the steel grade must have sufficient carbon and to choose the proper hardening temperatures taking into consider-
alloy content and be capable of achieving a certain surface hardness, ation the appreciably non-equilibrium nature of induction heating
case depth, and core strength. Low-alloy and medium-carbon steels may result in incomplete transformation and mixed as-quenched
with 0.4 to 0.55% C (e.g., SAE 1040, 15B41, 4140, 4340, 4150, structures. Metallographic evaluation helps reveal the presence of
1552) are commonly used in induction gear hardening. In some “ghost pearlite” and other upper transformation products in the as-
applications, high-carbon steels (SAE 5160, 1080, 52100) are used, quenched specimens that are associated with not fully transformed
as well as martensitic stainless steels, cast irons, powder metallurgy structures or with the presence of severely heterogeneous austenite
materials, and proprietary microalloy steels. before quenching. The degree of heterogeneity in the microstructure
It is important to have a sufficiently “friendly” prior microstructure of the as-quenched component can be reduced by increasing the
(structure of parent material) when induction hardening gears. It is hardening temperatures and by lengthening the time at the austenite
highly desirable to use sufficiently homogeneous (both: chemically phase temperature range.
and structurally) prior structures without excessive segregation and A number of studies have been conducted to quantify the effect
severe banding. Q&T microstructure with a hardness range of 30 to of heat intensities typical for induction hardening and prior micro-
36 HRC leads to fast and consistent steel response to induction hard- structures on the shift of critical temperatures and the ability to form
ening. In contrast, steels with large carbides (i.e., spheroidized steels) satisfactorily homogeneous austenite. Reference 1 summarizes the
have poor response to induction hardening requiring prolonged heat- results of those studies.
ing and higher temperatures for austenitization. A combination of Q&T prior structures result in a consistent response to rapid
high temperatures with longer heat time may lead to grain growth, induction hardening with minimum amounts of grain growth,
data scatter, and excessive gear distortion. Coarse martensite has a shape/size distortion, and required heating energy. These prior struc-
negative effect on tooth toughness and impact strength. These are tures are associated with a well-defined (crisp) pattern with a short
the reasons why steels in normalize and Q&T conditions are often transition zone and may also produce slightly higher than expected
used in induction gear hardening. hardness levels (when hardening medium-carbon steels) and deeper
case depths, and form greater compressive residual surface stresses
METALLURGICAL SUBTLETIES compared with other types of initial structures.
OF RAPID HEATING OF STEELS Normalized structures consisting of a uniformly distributed fine-
Rapid heating considerably affects the kinetics of austenite formation, grain mixture of ferrite and pearlite also provide a rapid response to
shifting it toward higher temperatures according to the continu- induction hardening, allowing one to reduce the required hardening
ous heating transformation (CHT) diagrams. Practically all of the temperatures and times almost as much as Q&T prior structures
carbon, which is present in the initial ferritic-pearlitic structure, for and resulting in fast and consistent transformations.
example, is contained in the pearlite. Therefore, regardless of rela-
tively high solubility of carbon in austenite, some minimum time is TOOTH-BY-TOOTH HARDENING OF GEARS
required during solid-state transformation (such as austenization) for As the name implies, each tooth is heated individually. The tooth-by-
carbon to be diffused from pearlitic regions into areas occupied by tooth method comprises two noticeably different techniques: tip-by-tip
ferrite. Therefore, it is required to create conditions conducive to the or gap-by-gap hardening. Presently, tip-by-tip hardening is rarely used
needed diffusion-driven processes in order to develop an essentially because the hardening patterns usually do not provide the needed
homogeneous austenitic structure with sufficiently uniform carbon fatigue and impact strength in the root area. This is the reason why
distribution before quenching that is desirable for the great majority the term tooth-by-tooth hardening is almost exclusively associated
42 gearsolutions.com

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 Figure 4. Some of the most popular inductor designs for tooth-by-tooth gear hardening [1].

with the gap-by-gap hardening method and terms sink requiring additional heat generation there. In
tooth-by-tooth and gap-by-gap hardening are often order to further increase the power density induced
used interchangeably. in the root, a stack of laminations is typically used
The tooth-by-tooth hardening can be applied as flux concentrators.
to external and internal gears and pinions, and it There is a variety of tooth-by-tooth inductor designs
requires the inductor to be symmetrically located to accommodate the vast variety of gear types, tooth
between two flanks of adjacent teeth (Figure 3, left profiles, and sizes. It can be designed to heat only the
image). Gears can be fairly large when hardening root and/or flange of the tooth, leaving the tip and
large gears and pinions (for example, mill, marine, tooth core tough and ductile. Some of the most popu-
and large transportation gears, etc.), with outside lar inductor designs are shown in Figure 4, including
diameters easily exceeding 3 m and can weigh sev- a “single-butterfly (Figure 4, left two images) and a
eral tons. Gears used in wind turbines are typical “double-butterfly inductor” (Figure 4, right image).
examples where tooth-by-tooth induction harden- Although the eddy current path has a single- or
ing is effectively used. Since most wind turbines are double-butterfly shape, when applied with a scan-
constructed on remote sites, the size and weight of ning mode, the temperature and hardness pattern
turbines in combination with the expenses associ- is distributed within the tooth root and flank quite
ated with their repair demand superior strength and uniformly. As an example, Figure 5 shows a variety
higher longevity of wind energy-generator compo- of tooth-by-tooth hardness patterns. These patterns
nents. This emphasizes the importance of taking provide an exceptional combination of fatigue and
steps to ensure the quality and repeatability of Figure 5. Examples of hardness wear strength as well as resistance to shock loading and
patterns. (Courtesy: Inductoheat).
hardness patterns. scuffing, which is very important for heavily loaded
There is a limitation to applying this method gears and pinions experiencing loads of appreciable
for hardening external and internal gears. Pitch magnitude. It is commonly recommended that for
diameters of external gears and pinions are typically greater than these applications, surface hardness should not be too high, typically
200mm (8in.) having coarse teeth (modules greater than eight). It in the range of 55 to 59 HRC. If surface hardness exceeds 61 to 62
is commonly required that the pitch diameter of an internal gear HRC, the gear might be too brittle.
exceed 250mm (10 in.). Due to relatively small inductor-to-tooth air gaps (0.8mm to 2mm
Gap-by-gap hardening is a time-consuming process. Scanning being typical) and harsh working conditions, these inductors require
rates can reach 10 mm/s and even higher (though 6 to 8mm/sec is intensive maintenance and precise set-up compared to hardening induc-
more typical). Power requirements for these techniques are usually tors that encircle the gear. Pattern uniformity is quite sensitive to inductor
quite low. This can be considered an appreciable advantage, because if positioning. Asymmetrical positioning results in a non-uniform hardness
gear spin hardening is used using encircling coils, a large gear would pattern. For example, an increase in the air gap between the inductor
require an enormous amount of power which could diminish the copper and the flank surface on one side will result in a reduction of
cost effectiveness of the heat-treating or make it not even feasible. hardness and shallower case depth there, altering the mechanical proper-
ties. Therefore, precise inductor fabrication techniques, its rigidity, and
INDUCTOR DESIGNS superior alignment techniques are essential. Special locators or electronic
As one can see from Figure 3, middle and right images, the path of tracking systems are often used to ensure proper inductor positioning
the induced eddy current has a butterfly-shaped loop. The maximum in the tooth space. Thermal expansion of metal during heating should
current density is located in the root area (the body of the butterfly). also be taken into consideration when determining the proper inductor-
This is the reason why this inductor style is also called a butterfly to-tooth gap. After loading and initial coil positioning, the process runs
inductor. Massive area below the tooth root “acts” as a potent cold automatically based on the developed process protocol.
FEBRUARY  2018 43

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 Figure 6. Example of undesirable softening of the areas adjacent to the hardened
area (tempering back) [1].

SELECTION OF PROCESS PROTOCOLS

Particular attention should be paid to electromagnetic end/edge
effects and the ability to provide the required hardness pattern in
the gear end areas, as well as along the tooth perimeter. To obtain
the required temperature uniformity, it is necessary to use a complex
control algorithm: Power vs. Scan Rate vs. Inductor Position. A short
dwell at the initial and final stages of inductor travel is often used.
Thanks to heat transfer due to thermal conduction, the dwell at the
end of inductor travel is usually shorter compared to the dwell at the
beginning of travel or is not applied at all.
Since the eddy current makes a return path through the upper
region of the flank and, particularly through the tooth tip, proper care
should be taken to prevent overheating the tooth tip. Overheating
of the tip can substantially weaken the tooth. Figure 7. Example of Inductoheat’s standard induction machine for tooth-by-tooth
With the scanning mode, two techniques can be used: a design con- hardening large gears. (Courtesy: Inductoheat).
cept where the inductor is stationary and the gear is moveable, and a
concept that assumes the gear is stationary and the inductor is moveable. the areas adjacent to the hardened area (tempering back). The
There can be appreciable shape/size distortion when applying main cause of undesirable softening/temper back is associated
tooth-by-tooth hardening. Shape distortion is particularly noticeable with the thermal conductivity phenomenon. Heat is transferred
in the last heating position where the last tooth can be pushed out by thermal conduction from a high-temperature region of the
0.1 to 0.8mm. There is a direct relationship between the volume gear tooth toward a lower-temperature region and is a function
of required metal removal and the grinding time. Thus, excessive of the temperature difference, distance and the value of thermal
distortion leads to a prolonged grinding operation and increases the conductivity. Most metals are relatively good thermal conductors.
cost. Repeatable distortion may be compensated for during gear During austenization, the surface temperature exceeds the critical
fabrication. Hardening every second tooth can minimize distortion. temperature A c3. Therefore, when heating one side of the tooth
Obviously this will require two revolutions to harden the entire gear. there is a danger that the opposite side of the tooth will be heated
Final grinding may be still required. by thermal conduction to an inappropriately high temperature.
Even though there might be appreciable distortion when hardening This may result in undesirable softening of previously hardened
large gears and pinions (e.g., mill, marine and large transportation areas (Figure 6).
gears, etc.) its magnitude is not typically as significant when com- Whether a hardened side of the tooth will be unacceptably
pared to carburized gears. Carburizing requires soaking of gears for softened depends upon several factors, including the applied
many hours (in some cases up to 30 hours or longer) at temperatures frequency, gear module, tooth shape, scan rate, hardness depth,
of 850°C (1,562°F) to 950°C (1,742°F). At these temperatures the etc. In the case of shallow hardness depths and thick teeth, the
large masses of metal expand to a much greater extent compared to root of the tooth, its fillet, and the dedendum area are typically
the case when only the surface layer is austenized. The expansion of not softened. The massive area below the tooth root serves as a
a large mass during prolonged heating during carburization and the heat sink, which helps to protect the hardened side of the tooth
contraction during cooling/quenching cycle “moves” the metal to a from tempering back.
much greater degree resulting in larger gear distortion. Conversely, the addendum and, in particular, tooth tip region
Besides that, large gears being held at carburizing temperatures for can be considered as an area of concern because there is a relatively
many hours have little rigidity; therefore they can sag and have a ten- small mass of metal. In addition, heat has a short distance to travel
dency to follow the movement of their supporting structures/fixtures from one (heating) side to the other (already hardened) side of the
during soaking and handling. With induction hardening, areas unaf- tooth (Figure 6).
fected by heat as well as areas with temperatures corresponding to the To overcome the problem of tempering back, special cooling spray
elastic deformation range serve as shape stabilizers and lead to not only blocks are applied. Additional cooling protects already hardened
lower, but more predictable distortion, which is easier to compensate. areas while austenizing unhardened side of the tooth. Even though
external cooling is applied, there still may be some unavoidable tip
CONTROL OF UNDESIRABLE TEMPER BACK softening depending on the tooth shape and process parameters.
One typical concern when applying tooth-by-tooth hardening This tempering back is typically insignificant, well controlled, and
is the challenge related to undesirable heating and softening of acceptable (Figure 5).
44 gearsolutions.com

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stom Gears

TOOTH-BY-TOOTH GEAR HARDENING EQUIPMENT of presently used inverters do not have such capability.
Applied frequencies are usually in the range of 3kHz to 30kHz and A new generation IGBT-type inverter (Statipower-IFP) recently
inductor powers of 50kW to 150kW range. At the same time, there developed by Inductoheat Inc. eliminates this limitation and simpli-
are cases when a frequency of 70 kHz and even higher frequencies fies achieving the required hardness pattern [2]. The patented tech-
have been used. Figure 7 shows an example of Inductoheat’s standard nology is specifically developed for induction scan hardening needs.
induction machine for tooth-by-tooth hardening large gears. It enables instant and independent adjustment of frequency (from
Tooth-by-tooth hardening can be applied for gears submerged in 5kHz to 60kHz) and power (up to 450 kW) in a pre-programmed
a temperature-controlled quench tank. This technique was applied manner during the heating cycle, optimizing electromagnetic, ther-
in the original Delapena (UK) induction hardening process. In this mal, and metallurgical conditions. The capability of IFP inverters
case, quenching is practically instantaneous. However, noticeably to instantly change power and frequency during scan hardening is
higher power is needed to compensate for the cooling effect of the essential for better control of end/edge effects, help to avoid edge
quenchant during heating. The fact that a gear is submerged in overheating and cracking, and it is particularly beneficial when hard-
quenchant also helps to prevent the tempering back problem. In ening a variety of gears with appreciably different tooth geometry
addition, the quenchant serves as a coolant to the inductor. Therefore, and case depth requirements.
in submerged hardening an inductor might not have to be water- This innovative technology effectively addresses industry needs for
cooled. On the other hand, there might challenges to set up this cost-effectiveness and enhanced process flexibility, greatly expanding
"Gear precision system grade"
because of quenchant obstruction issues. induction equipment capabilities and further improving metallurgi-
In induction surface hardening, applied frequency has the cal quality of induction hardening.
Gear precision grade
greatest effect on depth of heat generation and an appearance of
electromagnetic
Gear precision Grade end and edge effects. It is advantageous to apply REFERENCES
0 1 2 various
3 combinations
4 5 of frequency, power density, and scan rates 1. V. Rudnev, D. Loveless, R. Cook, Handbook of Induction Heating,
8 N4 N5 N6 N7
at various N8 N9
stages of the gear scan hardening cycle. This would Second Edition, CRC Press, 2017.
4 5 6 7 8 9
allow improving the metallurgical quality of teeth effectively 2. G. Doyon, V. Rudnev, C. Russell, J. Maher, Revolution – not
73)
13 12 10 addressing
9 8 the7 presence of end zones (sides of gear) as well as evolution – necessary to advance induction heat treating, Advance
14 12 11 specifics
10 of
9 gear8 tooth nomenclature. Unfortunately, the majority Materials & Processes, September, 2017, p.72-80.
13 12 11 10 9 8
11 10 10 9 8 7
ABOUT THE AUTHOR Dr. Valery Rudnev, FASM, is director of science and technology at Inductoheat, Inc., an Inductotherm Group company. More
able :
information is available at www.inductoheat.com. Some of the information presented here was first published in the Handbook of Induction Heating,
sponding materials of SCr415) is defined as
CM415. Second Edition, by V. Rudnev, D. Loveless and R. Cook, CRC Press, 2017. CRC Press has granted a permission publishing these materials.
ase hardening), SCM415 is normally used.
for harder material, SNCM220 and/or SNCM420

etermined by producti
ss value is inf

grade table :

Largest selection of
valent grades are for ref
ly match each other.

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15/05/21 14:20:18
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Phone: 516.248.3850 | Fax: 516.248.4385
Email: info@khkgears.us

FEBRUARY 2018 45

GS February 2018.indb 45 1/23/18 12:18 PM

 Custom gearbox. (Courtesy: CGI, Inc.)

46 gearsolutions.com 46 gearsolutions.com

GS February 2018.indb 46 1/23/18 12:18 PM

 Choosing a Planetary Gearhead
Motion projects featuring planetary gearheads excel in the areas
of system response, inertia matching, speed matching, system stiffness,
and system resolution.
From CGI Inc. staff

When a motor is being designed into a motion control

system, all too often the benefits of a gearhead are realized
much too late. Designing in a gearhead at the end of the
project will many times cause delay and additional cost,
which could have been prevented if it had been consid-
ered at the start of the project. Understanding all of the
advantages that a gearhead can provide becomes a neces-
sity when designing a successful motion control project.

GEARHEAD CONSIDERATIONS
When a motor is designed into a motion control system,
cost is generally the driving factor that influences the
concepts of the design. In keeping what is thought to be
auxiliary components to a minimum, a gearhead is often
disregarded in hopes that the motor itself can handle the
application. However, in many cases, the necessity of a
gearhead is understood when the use of the motor (alone)
then presents challenges, and it is usually at about the
Among the many reasons engineers should choose a planetary
time the project is due to ship to the customer. After the gearhead for their motion project are for improvements in system
initial design oversight, a gearhead is then determined to response, inertia matching, speed matching, system stiffness, and
be required, and it usually needs to be applied into a space system resolution. (Courtesy: CGI, Inc.)
that originally was never intended to accommodate a gear-
head. In short, the cost of redesigning a motion application use of a gearhead, you can achieve two separate, favor-
to incorporate a gearhead afterwards will usually prove able speeds; a speed that is optimum for the motor and a
more expensive than if it was designed in from the start. speed (resulting from the gearhead ratio) that is optimum
Among the many reasons engineers should choose for the application. When initially considered as part of
a planetary gearhead for their motion project are for the motion design, speed matching can produce greater
improvements in system response, inertia matching, component longevity for the application.
speed matching, system stiffness, and system resolution.
SYSTEM STIFFNESS
SYSTEM RESPONSE When a motion system lacks stiffness, a number of
System response and inertia matching are particularly unanticipated attributes can arise. Issues can include
important since sometimes the application inertia can be lost motion, system compliance, wind-up, harmonics
several times greater than the inertia of the motor, which can (ringing), unpredictability, premature wear, and system
then result in a sluggish and disappointing motion reaction. vibrations. This is where a gearhead can alleviate many
When you integrate a gearhead into the system, it decreases issues. The addition of a gearhead onto a motor can
the reflected load inertia at the motor shaft by the inverse of increase the motion system rigidity or stiffness in direct
the square of the gearhead ratio. What that really means is proportion to the gearhead ratio. Forces such as load vari-
that a gearhead can make a motor act as if it is magnitudes ance or back-driving (reflected) loads then become more
larger than it really is, and then it handles the load with easily managed with the use of a gearhead. The result will
power to spare. The ideal situation to accomplish is to have typically be a more reliable and precise system control
the motor rotor inertia equal to the application load inertia that eliminates those issues previously mentioned.
(or as close as possible), which will result in snappy system
response; this is exactly what a gearhead can do. INCREASED RESOLUTION
In addition to system improvements like swift response,
SPEED MATCHING greater power, extended longevity and maximum stiffness,
Besides giving a motor muscle, a gearhead can also offer a planetary gearhead can be a benefit to the system resolu-
the performance advantage of speed matching. Most tion. The better the system resolution is, the more precise
electric motors have an optimum speed (rated RPM) that the control of movement becomes. For example, a 10:1 ratio
they were designed to run at most efficiently. With the gearhead coupled with a motor will magnify the motor’s
FEBRUARY  2018 47

GS February 2018.indb 47 1/23/18 12:18 PM

 Custom gearbox. (Courtesy: CGI, Inc.)

positioning ability, resulting in more precise movements and better

accuracy at the application by a factor of 10. Motor Cogging or step size
(when using a stepper motor) is also directly reduced by the gearhead
ratio, providing a more consistent and smooth motion response.

APPLICATION KNOWLEDGE
Among the most important items of information an engineer needs
to firmly possess when evaluating the application is an acute aware-
ness of the motion profile and load requirements. Additionally,
understanding system elements such as torque profile, overhung
loading, system stiffness, sensitivity to backlash, duty cycle, envi-
ronmental concerns, life expectancy, and shock loading is necessary
for the success of a gearhead in a motion application. The more
application requirements that are known up front, the easier it is
to prioritize and balance what is needed when choosing the opti-
mum gearhead size, configuration and ratio. For example, a ratio
that optimizes speed matching may not work well with the target
inertia matching in some applications, so knowing the priorities Besides giving a motor muscle, a gearhead can also offer the performance advantage
and demands of a motion application is key. It becomes a juggling of speed matching. (Courtesy: CGI, Inc.)
act when trying to achieve all of your priorities when designing a
motion system, however, the benefits of using a gearhead will help
find the right balance in meeting applications objectives.

GEARHEAD SOURCING
High-quality products at a competitive price point is what every
gearhead company strives to offer, but when it comes to actually
using product, the differentiation becomes the type of support avail-
able when questions arise. Quick, insightful, reliable, and world-class
global experience support is critical to a successful application. It’s
key to find engineering and sales support teams that are ready to
help you find the products that best suit your application needs as
well as providing you with a long-term support relationship. On-time
delivery is critical in meeting custom requests for both small and
large quantities. Last but not least, you want to be comfortable with
the capabilities, technology, culture, and longevity that the com-
pany possesses. This can include engineering, manufacturing, and
quality departments use the latest systems available in 3D model-
ing, FE analysis, CAD/CAM, scanning CMM technology and an
all-inclusive ERP inventory management system.  VPX Series “Victory” Value planetary gearbox. (Courtesy: CGI, Inc.)

ABOUT THE COMPANY  CGI, Inc. was founded in 1967 and is in Carson City, Nevada. Serving the medical, robotics, aerospace, consumer, defense,
industrial, and energy markets, among others, it is ISO 9001:2008 certified and a member of the American Gear Manufacturers Association. For more
information: www.cgimotion.com or www.cgiprecision.com.

48 gearsolutions.com

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 PRODUCT NEW PRODUCTS, TRENDS,

SHOWCASE SERVICES, AND DEVELOPMENTS

SAMAG MACHINING CENTERS,

DEEP DRILLING MACHINES AVAILABLE
IN NORTH AMERICA
Now available from German Machine Tools of America (GMTA),
a full line of Samag multi-spindle machining centers is offered for
the North American market.
Samag, based in Saalfeld, Germany, with offices and service
centers worldwide, engineers and builds a variety of multi-spindle
machines, the MFZ Series for high volume cubic work pieces. Samag
multi-spindle horizontal machining centers, used primarily for high- Samag has developed the modular construction kit for the new MFZ series
volume parts, are now offered to the automotive powertrain, truck, consistently from the point of view of the workpieces to be machined. (Courtesy:
off-highway, and other markets. German Machine Tools of America)
The company supplies complete turnkey solution, including tool-
ing, work holding, robotic articulation, parts handlers and transfer and the extendable tool magazine allow the machining of diverse
mechanisms for high-production work such as knuckles, engine workpiece dimensions and capacities. All models are available with
blocks, gearboxes, valves, and connecting rods. a linear or ball screw drive and up to four working spindles. Five-
With “FIT 2 PART,” the modular construction kit of the multi- axis simultaneous machining and a workpiece feed during primary
spindle horizontal machining center has been developed consistently processing time is possible. The rock-solid machine bed, filled with
from the point of view of the workpiece. Attention was focused on Hydropol®, is thermally stable and possesses excellent damping abili-
flexibility; among others, the X Y Z axes of the two-spindle machine ties. Users benefit from productivity increase, flexibility, precision,
can be corrected independently of one another. Four sizes and two and energy-efficiency.
types of drive offer options for high-speed machining and heavy-duty
cutting. The number of spindles, the variable distance between them, FOR MORE INFORMATION: www.gmtamerica.com

The P 16 G
KLINGELNBERG PRESENTS SMART
Precision
Measuring MEASURING TECHNOLOGY AT METAV
Center.
(Courtesy: METAV, the International Exhibition for Metalworking Technologies,
Klingelnberg) will mark its twentieth year as the innovation showground for manu-
facturing technology. Represented in the Quality Area Forum with
the P 16 G Precision Measuring Center, Klingelnberg, along with
other companies, will show that measuring technology is an essential
pillar of smart data and big data concepts.
Scheduled for February 20-24, more than 600 exhibitors
from more than 20 nations will present their latest metalwork-
ing technologies at this year’s METAV in Düsseldorf, Germany.
The exhibition hosted by the German Machine Tool Builders’
Association (VDW) is now in its twentieth year, and will once again
provide a comprehensive overview of the entire value chain. The four
areas of the chain (additive manufacturing, medical, molding, and
quality) represent a microcosm of contemporary industrial manu-
facturing. Gear specialist Klingelnberg will enjoy a well-positioned
presence in the Quality Area in Hall 16, Stand A13, focusing in
this forum on its “non-gear” expertise with the P 16 G Precision
Measuring Center.
Whether turning blanks, ground workpieces, circular blades,
spacers for circular blades, or ball bearings, the new P 16 G
Precision Measuring Center is purpose-designed – not to measure
FEBRUARY  2018 49

GS February 2018.indb 49 1/23/18 12:18 PM

 gear teeth, but rather specifically for use in manufacturing axially Stringent precision requirements in series production and increas-
symmetrical components. It is the only machine in Klingelnberg’s ing component complexity both call for the best available measuring
P series to be equipped with software for dimension, form, and technology. The P 16 G is optimally designed for the production
position measurement as standard. The software records diameter process, suitable for direct shop floor use, and can be employed
and cylindrical form/conicity; measures axial runout, evenness, along the entire production chain. After each manufacturing step,
and angularity; and delivers a wealth of information for quality every feature can be immediately displayed graphically or in table
management, as required. With this precision measuring center, format, analyzed, and statistically evaluated. This enables efficient
there’s no need for gauges. In terms of quality assurance, this uni- process control and reliable management of production processes.
versal solution for axially symmetrical components provides new The basic software also includes storage of statistical data for further
opportunities to make a vital contribution to success, particularly in evaluation, such as warning limit specifications. And the P 16 G is
times of highly accelerated innovation cycles and growing require- incredibly easy to operate.
ments. Measuring and testing technology has become an essential
pillar of smart production concepts. FOR MORE INFORMATION: www.klingelnberg.com

CRC PRESS PUBLISHES ‘GEAR CUTTING TOOLS: SCIENCE AND ENGINEERING’

Dr. Stephen P. Radzevich is a professor of mechanical engineer- • Develops methods for generating working surfaces of gear cut-
ing and manufacturing engineering, and has extensive industrial ting tools.
experience. He has spent more than 40 years developing software, The second edition of Radzevich’s Gear Cutting Tools:
hardware, and other processes for gear design and optimization. He Fundamentals of Design and Computation presents the DG/K-
has authored numerous books and scientific papers on gear technolo- based method of surface generation, a practical mathematical
gies, and holds patents for inventions in the field. method for designing gear cutting tools with optimal parameters.
Gear Cutting Tools: Science and Engineering is published by CRC press. The text addresses gear cutting tool evolution, and proceeds to
Among the book’s features: scientific classification for all types of gear machining meshes
• Presents a powerful scientific method for designing of optimal before discussing optimal cutting tool designs. Designs currently
gear cutting tools. used and those being planned are covered, and the approach allows
• Outlines an analytical method that can be incorporated into for development of scientific predictions and optimal designs.
modern CAD/CAM systems. Solutions appear in analytical form and/or graphical form, with a
• Explains methods for computing accuracy of the machined gears wealth of new figures added, and new appendices offer additional
and optimal cutting-edge geometries. data for readers.
• Includes the newest designs of gear cutting tools, detailing optimal
design parameters. FOR MORE INFORMATION: www.crcpress.com

KISSSOFT SYSTEM DESIGN DATA INTERFACE SAVES TIME, OFFERS EFFICIENCY

KISSsys is KISSsoft’s system add-on that enables you to model
complete gear units and drive trains. KISSsoft calculates the service
life and strength of the different machine elements, and transfers
the results to KISSsys, where they are displayed in clear overviews.
To achieve this, KISSsys brings together kinematic analysis, 3D
graphics, and user-defined tables and dialogs.
KISSsys allows the users to perform system-level evaluations in one
run, while considering the interdependent effects of all components
of the gearbox on one another. System reliability, load spectrum
calculation, efficiency and thermal balance evaluation, and modal
analysis are now available, and more. And all that with consideration
of all possible misalignments calculated in KISSsoft, coming from
shaft deflections, planet carrier deformations, bearing stiffnesses,
thermal effects, and others.
With GEMS™, Gleason has introduced the next generation design
and manufacturing system for bevel gears. It is a powerful new
software platform that provides highly desirable gear design and
analysis capabilities, seamlessly connects with existing Gleason
design software – and helps optimize the complete bevel gear manu- KISSsys brings together kinematic analysis, 3D graphics, and user-defined tables and
facturing process. dialogs. (Courtesy: KISSsoft AG)
• Easy connection to, and transfer of data with, CAGETM,
UNICALTM, and common design software. • Interface with GEMS through touchscreen or conventional mouse/
• Import of files from CAGE and UNICAL. keyboard.
50 gearsolutions.com

GS February 2018.indb 50 1/23/18 12:18 PM

 • 3D gear and pinion graphics with animation. between the bevel set and shaft modules in KISSsys, KISSsoft
• Combined ease-off and TCA for pinion and gear. determines the EPG misalignments of the gears, taking shaft-
• Interactive tooth surface and ease-off correction and optimization. bending values into account. These results are then transferred
• Real blank geometry for both pinion and gear. to GEMS, which carries out a comprehensive contact analysis for
• 2D tooth profiles along the face width. each load case specified by the user in KISSsys. All the impor-
• 2D/3D loaded TCA, including interactive root bending stress and tant results such as transmission error, meshing stiffness, root
contact stress output with S-N Curves. stresses, or even contact pressure on the flanks of the pinion and
• Interactive tool design with graphical slot and blade output. the wheel can finally be displayed in KISSsys after transferring
GEMS and KISSsys programs are now linked by a direct inter- back the result data from GEMS. This process allows the user to
face to exchange gear tooth and system design data between the evaluate and optimize in a more accurate way any type of bevel
two software packages. From a gearbox model in KISSsys, GEMS or hypoid set with a closed loop between the simulation and the
supplies the values for the geometry data of a selected bevel gear manufacturing processes.
pair, which is imported and directly set in the corresponding
KISSsoft calculation. Thanks to the automatic communication FOR MORE INFORMATION: www.kisssoft.ag

The Tendo Platinum toolholder by Schunk is an

advanced technology toolholder promising durablity,
ease of use, and precision. (Courtesy: Schunk)
Polymat series of

SCHUNK COMPLETES From simple keyways to

CNC keyseating
machine
RANGE OF PRECISION multiple, special profiles,

TOOLHOLDERS Leistritz Polymat

and Polyjet
The Tendo Platinum toolholder by Schunk is
an advanced technology toolholder promising machines have
durablity, ease of use, and precision for almost
any milling, drilling, and reaming application. the features
Tendo Platinum has improved brazing
to improve
technology by using a unique brazing and
hardening process all in the same cycle, which quality, shorten
allows for the most rigid and durable tool
clamping available. Being manufactured from cycletimes and
highest-grade tool steel and hardened to ensure
long life, this toolholder is ranked among the minimize set-ups.
highest of its kind in terms of quality standards
and exceeding industry tolerance norms and
material specifications
With excellent vibration dampening and
precise run out accuracy of less than 0.003
mm (0.0001”) at 2.5 x clamping diameter,
the Tendo Platinum works in configuration
with the machine spindle and the cutting
tool to reduce wear and damage.
Schunk offers direct clamping in both Leistritz Advanced Technologies Corp.
metric and inch sizes to assure the best 165 Chestnut Street, Allendale, NJ 07401
accuracy and vibration dampening. 201 934-8262
www.leistritzcorp.com
FOR MORE INFORMATION:
www.us.schunk.com
FEBRUARY  2018 51

GS February 2018.indb 51 1/23/18 12:18 PM

 SANDVIK COROMANT SOFTWARE BOOSTS FIVE-AXIS MACHINING CENTERS
Cutting tool and tooling system specialist ity level 6 or better (according to DIN 3962). gap), and straight bevel gears (expected at
Sandvik  Coromant  has extended the func- After entering the required gear data, the end of 2017), an additional function avail-
tionality of its InvoMilling™ software. The intuitive CAD/CAM software defines the able in the latest version of InvoMilling™ is
latest version of this user-friendly CAD/ optimum machining strategies and generates flank correction. This applies to tip relief
CAM solution for fast and simple NC pro- a CNC program that allows the production and crowning in both the flank and profile
gramming offers more possibilities when of different gear profiles using just a few directions as well as helix and pressure
manufacturing gears on universal five-axis standard precision tools. The software also angle corrections.
machining centers. offers excellent graphics as well as features to “With the new software functionalities
InvoMilling™ exploits machine tool kinet- create and simulate milling paths. and tool optimizations, we are offering
ics for the effective and flexible manufactur-   As well as upcoming options for her- our customers additional options for gear
ing of high-quality gears and splines in qual- ringbone, double helical (with and without cutting in small and medium batch sizes
—making the process even more flexible,
fast, and efficient,” said Jochen Sapparth,
product manager  InvoMilling™ CAD/
CAM at Sandvik Coromant. “At the same
time, we are expanding the range of appli-
cations that can be performed using five-
axis machining centers.”

FOR MORE INFORMATION:

www.sandvik.coromant.com /en-gb

JM PERFORMANCE
PRODUCTS ADDS
SPINDLE KITS
CNC spindle maintenance is treated as
a dirty, boring, and often overlooked job.
A clean spindle is essential for proper taper
contact between the spindle and v-flange
toolholder.
JM Performance Products, Inc. (JMPP:
Fairport Harbor, Ohio), a leading manufac-
turing innovator of CNC mill spindle opti-
mization products since 2009, has developed
its advanced Spindle Cleaner Kit and Spindle
Restoration Kit.
The spindle cleaners and spindle restora-
Jobs always ship within a week — tion tapers are made from anodized alumi-
num that will not collapse in the spindle
DEFINITELY no complaints! Thank you during use. They also come with removable
all for doing such an awesome job! handles that can be used with all cleaning
Keep up the great work! and resurfacing head tapers.
The cleaner kit is designed to remove loose
oil, debris, and other contaminants from
Gear Manufacturer / Southeast USA CAT and BT spindles in 30, 40, 45, 50, or
60 taper sizes. The restoration kit is designed
to remove high spots attributed to debris
and rust that has galled to the surface of
1.800.569.1420 the spindle and cannot be removed through
www.McInnesRolledRings.com cleaning.
533 E 12TH STREET • ERIE, PA 16511
FOR MORE INFORMATION:
www.jmperformanceproducts.com
52 gearsolutions.com

GS February 2018.indb 52 1/23/18 12:18 PM

 MACHINERY CONTACT GEAR SOLUTIONS AT
800-366-2185 TO LIST YOUR MACHINERY.

Barber Colman 4-4, Index Plates, Very Light Use, Excellent  REF#102 GEAR GRINDERS
FEATURED SUPPLIERS Gleason 538, 18” Shaper Blades, Makes Blades from Blanks, Light Use, Extras  REF#102
Star 2VHS, 6” x 6”, Coolant, Change Gears  REF#102 #27, #137, and #463 Gleason Hypoid Spiral Bevel gear grinder generating Cams
Gibbs Machinery Company – REF #102 (2 full sets)  REF#105
Phone: 586-755-5353 Fax: 586-755-0304 GEAR SHAPERS CNC Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing  REF#105
Reishauer NZA, 12”, Fassler Dresser, Many Extras, 1994  REF#102
Email: rj@gibbsmachinery.com
36” Shapers, 14” Throat Risers, 53” of Swing, Qty 3  REF#105 Reishauer RZP, 4-8”, Auto Loading, High Production, Use in Lab  REF#102
Website: www.gibbsmachinery.com
FELLOWS #10-4/10-2, Qty 150  REF#105 Reishauer RZ301AS CNC, 13” Measuring System (3)  REF#102
Havlik International Machinery, Inc. – REF #103 HYDROSTROKE #50-8, Qty 2  REF#105 Reishauer ZB, 27.5” PD Gears, Coolant  REF#102
Phone: 519-624-2100 • Fax: 519-624-6994 HYDROSTROKE #20-8, Qty 5  REF#105 Gleason 120 Curvic Coupling, 24” Max. Dia., Index Plates, Extras  REF#102
HYDROSTROKE #FS630-125, Qty 1  REF#105 Csepel FKP-326, Fassler Dresser, Like A Hogland NZA Reishauer, Super Cond.  REF#102
Email: havlik@bellnet.ca
HYDROSTROKE #FS400-90, Qty 2  REF#105 National Broach SGK-24, Max. OD 31”, ID 24”, Spur & Helical, From Aircraft  REF#102
Website: www.havlikinternational.com
FELLOWS #20-4, Qty 6  REF#105 Maag SH150, 60”, Change Gears, 2-Pitch, Max. Face 23-1/2”, Navy Surplus  REF#102
General Tool & Engineering Company - REF #107 FELLOWS #48-8Z, Qty 1  REF#105 ZSTZ 800 WMW Niles  REF#107
Phone: 501-945-7111 • Fax: 501-945-7111
Email: generaltoolandengineering@hotmail.com GEAR SHAPERS GEAR SHAVERS

Midwest Gear Corporation – REF #104 FELLOWS #10-2, (10” Dia), 2” Face  REF#105 Red Ring GCU 12” Crowning, 1956 to 1988 (6)  REF#102
Phone: 330-425-4419 • Fax: 330-425-8600 FELLOWS #10-4, (10” Dia), 4” Face  REF#105 Rex Ring GCX 24”, Crowning, 12” Cutter Head, Taper Attachment, Long Table  REF#102
Email: sales@mwgear.com FELLOWS (200) 10-4 / 10-2 Shapers  REF#105 Mitsubishi FB30, 12.2 CNC Fanuc, 1997  REF#102
Website: www.mwgear.com FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/ 6 axis 16iMB Fanuc (2009)  REF#105 Michigan 870, Crowning, Power Stocks, Very Light Use, Excellent  REF#102
FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/ 6 axis 16iMB Fanuc (2009  REF#105 National Broach GCY 18”, Crowning, Max. 19=1/2”, Rebuilt or Under Power  REF#102
New England Gear – REF #105 FELLOWS (1) #7 125A Face Gear Machine  REF#105 National Broach GFF, Crowning, Heidenhein Scales, Servo Drives, 1993  REF#102
Phone: 860-223-7778 • Fax: 860-223-7776 FELLOWS (2) #3 Face Gear Machine  REF#105 Raso Sicmat 400 CNC, Fanuc 16iM, Chip Separator, 2001  REF#102
Email: jeff@newenglandgear.com (1) 4ags with adjustable Helical Guide s/n 30634  REF#105
Website: www.newenglandgear.com (1) #7 125A adjustable Helical Guide  REF#105 GEAR TESTERS/CHECKERS (INCL CNC)
FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc Controller (2009)  REF#105
Phoenix Tool & Thread Grinding – REF #106 FELLOWS (2) Swing-away center support for 10-2 / 10-4  REF#105 FELLOWS (1) RL-600 Roll Tester s/n 35814  REF#105
Phone: 216-433-7008 • Fax: 216-433-7067 FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/ 6 axis 16iMB Fanuc FELLOWS (1) 24H Lead Checker s/n 32289  REF#105
Email: phoenixthread@yahoo.com (2009)  REF#105 GLEASON (1) #14 Tester s/n 31907  REF#105
Website: www.phoenixthreadgrinding.com FELLOWS (2) FS400-170 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009)  REF#105 GLEASON (1) #6 Tester s/n 19316  REF#105
FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009)  REF#105 FELLOWS (1) 20 M Roller Checker  REF#105
FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis 21i Fanuc Controller (2009)  REF#105 FELLOWS (1) 20 M w/ 30” Swing Roller Checker  REF#105
GEAR ACCESSORIES, PARTS & TOOLING FELLOWS (1) 48-8Z Shaper w/ 14” throated riser (53” of swing)  REF#105 FELLOWS (1) #8 Micaodex s/n 36279  REF#105
FELLOWS (1) Horizontal Z Shaper s/n 21261  REF#105 Fellows 24M Involute, Response Electronic Recorder, Hot Pen  REF#102
FELLOWS Model #10-4/10-2, All Parts Available  REF#105 FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB 4 axis Fanuc controller Fellows 36” Space Tester, Hot Pen Guaranteed  REF#102
Tilt Tables for 10-2/10-4, Qty 2  REF#105 s/n 34326  REF#105 Fellows 8M Redliner, 13 5/8”, Recorder (2)  REF#102
FELLOWS (1) 36-10 Gear Shaper  REF#105 Gleason 6, 7-1/2” Indicator Check, Pinion .00015, Gear .00001  REF#102
GEAR HOBBERS/CUTTERS CNC FELLOWS (1) 10x6 Horizontal Z Shaper  REF#105 Gleason 17A Running or Rebuilt Guaranteed  REF#102
FELLOWS (1) 36-6 Gear Shaper w/ 13” riser s/n 27364  REF#105 Gleason 511, 20” Reconditioned in 2010 Guaranteed  REF#102
Pfauter PE150, 15MB Fanuc, Chip Conveyor, Auto Load  REF#102 FELLOWS (1) 10-4 Shaper w/ 3” riser w/ 4 axis 21i Fanuc Controller (2009)  REF#105 Gleason 502, 10”, Hydraulic Chucking, Automatic Backlash, Eliminator  REF#102
Pfauter PE150, Siemens 3M, Magnetic Chip Conveyor, Oil Chiller  REF#102 All Parts for 10-4/10-2 Fellows Gear Shapers  REF#105 Gleason 513 20” Gear, 10’ Pinion Electronic Meter Reading of Sound (3)  REF#102
Pfauter PE150, Fanuc 15, with light hob slide 8”  REF#102 Gleason 515, 24”  REF#102
Pfauter PE80, 15MB Control, Auto Load, Light Curtain  REF#102 GEAR DEBURRING/CHAMFERING/POINTING Gleason 520, 30”, Hyd. Chucking, Auto Splash Doors/Backlash, Eliminator  REF#102
Liebherr LC82 15M Fanuc Control, Auto Load  REF#102 Gleason 523, 20” Reconditioned, 2010  REF#102
Liebherr LC502, 20”, Fanuc 16im, 2007  REF#102 Cross 55 Gear Rounder, 18” Chuck, Hydraulic Unit  REF#102 Gleason 528 Cutter Inspection, Proximity Type Gage, 3.5”-25”, Conventional  REF#102
Liebherr LC380, 440mm W/100mm Hob, 2008  REF#102 Cross 65, 10” Gear Pointer, Power Cylinder, Cutter, Change Gears  REF#102 Illinois 1731-3C, Hob & Worm Lead Tester, Electronic Recorder, Master Hob  REF#102
Cross 85 10” Chamfer, (2) Cutter Heads, Bevel, Spur, Helical  REF#102 Illinois 3412B-3C, 12” Involute with 1606 Electronic Recorder, Master Gauge  REF#102
GEAR HOBBERS/CUTTERS Samputensili SCT3 13.7”, SM2TA 10”, (5), 2003  REF#102 Illinois 3824-1-3B Spline & Spur Lead Tester, Max. Centers 52”,
Samputensili SM2TA, 10”, Max. Face Width 4”, Hyd. Work Clamping, 1983-2003  REF#102 1606 Recorder  REF#102
TOS OFA Series Conventional Gear Hobbers, 12” & 40” Dia  REF#103 Mitsubishi MA30 CNC, 11”PD, Fanuc Control, Powermate, 1999 (2)  REF#102 Illinois 3912-3C Lead Tester, 12”, 1607 Electronic Recorder, 1980  REF#102
TOS OHA Series Conventional Gear Shapers, 12” & 40” Dia  REF#103 Klingelnberg PFS600 W/Masters, Recorder, Extras, 23.6”, 0.59-23.6”  REF#102
PFAUTER P1251 Hobbers s/n 25-276 and 25-277  REF#105 GEAR HONERS M&M 3015, 15” Gear Analyzer, P2 Computer Software, 12”Mag. Chuck  REF#102
PFAUTER (1) RS-00 s/n 17593  REF#105
BARBER COLEMAN (1) 16-36 multi cycle s/n 4404  REF#105 National Broach GHG 18”, Power Stock, Crowning, Variable Speed  REF#102 GEAR THREAD & WORM, MILLERS/GRINDERS
Lees Bradner 7VH, 8”PD, 10” Face, , Magnetic Chip Conveyor , Hob Shift  REF#102 Toyo T465 CNC, 160M Fanuc 5-Axis, Power Stock, Uses Fassler Tooling,  REF#102
Lees Bradner 7VH, 8”PD, 4PD, Magnetic Chip Conveyor, Hob Shift  REF#102 Ex-Cell-O 36 External Thread Grinder  REF#106
Barber C. 16-15, 4” Hob, Crowning, Differential, Double Cut, 3 DP, 1977  REF#102 GEAR GENERATORS Jones & Lamson 12 x 45 Automatic Thread Grinder  REF#106
G & E 36H, 36”, Hi-Column, Differential, From AEM Toolroom, Excellent  REF#102 Lees Bradner HT 12 x 54 Thread Miller  REF#106
G & E Model 48HS, 48”PD, 18” Face, 2.5 DP, Hi-Column, Heavy Duty, 8” Hob REF#102 Gleason 11 Spiral Bevel, 13”, Stock Divider, Hyd. Chucking, Roughers & Finishers  REF#102
Liebherr L301, 12” Crowning, Double Cut, Differential, Hob Shift  REF#102 Gleason 12”, Gears, Gauges Tool Blocks  REF#102 MISCELLANEOUS
Liebherr L401, 16”, Differential, 2-Cut Cycle, Chip Conveyor, 7.566” Hob Dia.  REF#102 Gleason 16 Spiral Bevel, 18”, 2-1/2 DP, Modified Roll, Chip Conveyor  REF#102
Liebherr L402, 2-Cut, Infeed, Differential, Tangential Feed, 19.3 OD W/4” Hob  REF#102 Gleason 24 Rougher, Gears, Finishing Tool Holder  REF#102 WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80” Centers,
Cleveland 1886, Hi-Helix, Hob Head, Auto Hob Shift, 4-Pitch, 1975  REF#102 Gleason 116 Rougher & Finisher (6)  REF#102 12” Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965  REF#104
Gleason Phoenix 175HC CNC – 1994  REF#102 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing  REF#105
GEAR HOB & CUTTER SHARPENERS (INCL CNC) Gleason 22 Rougher & Finisher (8)  REF#102 TOS SU & SUS Series Conv Lathes  REF#103
Gleason 26 Spiral Bevel, 33-36”, Mod. Roll, Stock Divider, Coolant, Change Gears  REF#102 TOS SUA Series CNC Flat-Bed Lathes  REF#103
TOS OHA Series CNC Gear Shapers, 12” & 40” Diameter  REF#103 Gleason Phoenix 450HC, Spiral Bevel, 150MB Fanuc  REF#102 Gleason: Change Gears, Cutter Heads, Cams, Index Plates, Workholding  REF#102
TOS OFA Series CNC Gear Hobbers, 12” & 40” Diameter  REF#103 Gleason 610 Combination Rougher & Finisher, 1988  REF#102 G & E: Change Gears, Arbors  REF#102
Barber Colman 10-12, Water Guards, Dresser, Index Plates  REF#102 Gleason 608 & 609 Rougher & Finisher  REF#102 Barber Colman: Change Gears, Arbors, Parts for All Models  REF#102
Star 2VHS, 6”x6”, Coolant, Change Gears, REF#102 Gleason 645 Spiral Bevel, Helical Motion, Chip Conveyor, Variable Rate of Roll  REF#102 Liebherr: Change Gears, Parts  REF#102
Star 4 x 4 (G691), 0-7000 Spindle Speeds, Auto Cycle, Coolant  REF#102 Gleason Cutters, 3” to 25” in stock, 1000  REF#102 Reishauer: Wheel Mounts  REF#102

FEBRUARY  2018 53

GS February 2018.indb 53 1/23/18 12:18 PM

  

 
  KORO for Quality  
Hob Sharpening Service
 Quick Turnaround 2 Day Service  

MARKET
 Spur Shaper Cutter Sharpening · Custom gear racks in AMERICAN and
 HSS & Carbide Hob with center hole   METRIC standards, STRAIGHT and

PLACE
HELICAL, VARIOUS materials, FINE and
and straight flutes COARSE pitch (254 D.P. – 0.5 D.P.; 0.10
 Thin Film Coatings Module – 50 Module); hard-cut (up to
  60 Rc) and soft-cut (up to 40 Rc); 32”
 Length up to 7 inches face width; Up to 82” lengths – longer
lengths through resetting
  · Custom gears in AMERICAN and
METRIC standards (3 D.P. – 72 D.P., 10”
Contact Gear Solutions  Diameter up
to 5 Inches
Diameter)
· Precision Quality up to AGMA 12
at 800-366-2185 to feature your  Precise rake   · Prototype & Production quantities
· Breakdown Service Available
and spacing guaranteed · Reverse Engineering
business in the Marketplace! to AGMA standards  
· Unique Tooth Configurations
· Heat Treating
 RUSH SERVICE AVAILABLE · Complete CNC Machining

Koro Sharpening Service

9530 85th Ave North  
Maple Grove, MN 55369
763-425-5247
info@koroind.com  

 
Achieving Increased Profits
and Response Times
FACE IT!
 
As a leading global technology
  provider, this customer decided to
move their existing facility to a
  new location so they could
continue to grow and advance.
As such, any new equipment they
chose needed to ...

Discover this
customer’s
winning our tools are just the best.
outcome:
303-447-1130
421 SE Bailey Road • Lee's Summit, MO 64081
www.kapp-niles.com
go.IpsenUSA.com/Customer-Stories
sales-usa@kapp-niles.com

Gear Careers Gear Careers 6/22/2017

072017_KappAd_NinthPage.indd 1 3:39:30 PM

BUSINESS CONTROLLER
DEV. LEADER With strong accounting skills
With manufacturing industry and and extensive experience in a
sales supervisory experience to manufacturing environment.
grow sales. Email your resume to: Email your resume to:
kyoung@forestcitygear.com kyoung@forestcitygear.com

forestcitygear.com/careers forestcitygear.com/careers

54 gearsolutions.com

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 ADVERTISER UNITE-A-MATIC™

INDEX SHOP HARDENED GEAR INSPECTION

WITH DATA COLLECTION
TRUE DIMENSION GEAR INSPECTION™

CONTENTS PAGE NO.

SOFTWARE HIGHLIGHTS
ALD Thermal Treatment Inc.................................................................13 • Real Time Data Collection
• Gauge R&R Studies
• Gauge Database Management
All Metals & Forge Group.....................................................................29

American Precision Gear Co................................................................55

REPORTING HIGHLIGHTS
Circle Gear & Machine Co Inc..............................................................11
• Analyze Inspection Data
• Compare Data and Process Behavior
• Customized Reporting
Engineered Tools Corporation..............................................................14
• Real-Time Reporting
Forest City Gear...................................................................................54

Gleason..................................................................................................2

Induction Tooling Inc............................................................................12

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

Ipsen............................................................................................. IFC, 54
*NO ANNUAL SOFTWARE FEE

KAPP Technologies........................................................................19, 54

KHK-USA.............................................................................................45
www.unite-a-matic.com

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

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

Lawler Gear Corporation......................................................................54

Leistritz.................................................................................................51 WWW.AMGEAR.COM
McInnes Rolled Rings..........................................................................52

Mitsubishi Heavy Industries America Inc............................................BC

New England Gear.................................................................................7 AEROSPACE/DEFENSE

NORDEX...............................................................................................25

Penta Gear Metrology LLC..................................................................37

Proto Manufacturing Ltd........................................................................9

CONTROLS
Russell Holbrook & Henderson Inc......................................................23

SMT......................................................................................................35

STD Precision Gear & Instrument Inc..................................................39

MEDICAL DEVICES
Stor-Loc..........................................................................................39, 54

CUSTOM PRECISION GEARS

The Broach Masters Inc.........................................................................4

Toolink Engineering Inc..........................................................................1 ISO2015, AS9100, DDTC

SALES@AMGEAR.COM
United Tool Supply.......................................................................55, IBC
FOSTER CITY, CA
Walker Forge........................................................................................33 800-554-3150
Wickert USA.........................................................................................23

FEBRUARY  2018 55

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 Q&A
MIKE HELM
MANUFACTURING ENGINEERING MANAGER,
OERLIKON FAIRFIELD

What are your duties with Oerlikon Fairfield? What’s What sets Oerlikon
a typical day like for you? Fairfield apart when it
I am responsible for our manufacturing engineering that supports comes to what you can
our shop floor, as well as supporting all new part development offer a customer?
and our quoting process. Most of my time is spent with my team, Our sweet spot is typically with medium-volume applications that
coaching and training — passing along what I have learned during require high-torque output. For loose components, we produce gears
my almost 40 years here. I also spend time with our sales team, up to two meters in diameter and shafts up to three meters in length.
resolving technical issues that our customers may have — without For finished gearboxes, we produce everything from small drives,
our customers we have nothing. which output 800 Nm of torque to gearboxes weighing over 15,000
pounds and generating over 400,000 Nm of torque.
What products and services does Oerlikon Fairfield offer? We have over 600 machine tools in our facility, most of them new,
It is important to understand that we are part of a much larger so that is a lot of machining capability. But, what really sets us apart
group (Oerlikon Drive Systems) with gear facilities spread around is our design support. We have a large engineering group, which can
the world. Globally, our group manufactures gears, axle assemblies, supplement or replace our customer’s resources. Our engineers have
gearboxes, and synchronizers for a wide range of industries covering extensive experience across a wide range of applications, and many
both on and off highway and industrial applications. Here, at our OEMs come to Oerlikon Fairfield to solve performance challenges
location in Lafayette, Indiana, we produce custom gears, as well as with their existing products.
sub-assemblies and finished gearboxes. We
produce our own range of planetary drives
under the Torque-Hub® brand, as well as
build to print and custom designs for OEMs
needing engineering support.

What is Oerlikon Fairfield doing

to advance the gear industry?
Oerlikon Fairfield has been a member of
AGMA for over 50 years. During that time,
we have contributed to the standards and
participated on the technical committees.
Our employees have been past presenters
at the fall technical sessions. Currently,
we have about 85 active patents for both
processes and gear designs. And some of
our latest are system patents for driveline
technology used on hybrid electric vehicles.

What are some of Oerlikon Fairfield’s

proudest moments?
I think our proudest moment will actually
come next year. We were founded in 1919, so we are about to celebrate Where do you see Oerlikon Fairfield in 10 years?
our centennial; 100 years is a long time to be producing gears and I think our industry will continue to see improvements with processes
motion drive products. and materials used in gear manufacturing, and I would hope we
During that time, our facility in Lafayette has grown to be remain at the leading edge of those future developments. Over time,
one of the largest of its kind in the industry. We have hundreds I would expect that we will move into higher volume applications,
of employees and extensive machining capability spread across which require a different manufacturing footprint. And I believe
600,000 square feet of manufacturing. We even have about 75,000 our services and product offering for finished drive assemblies will
square feet dedicated to heat treating. All of that is a testament to become more complex, requiring integrated drive options (electric
our employees, who have made careers here and built this business or hydraulic), and including technology for things like condition
across several generations. monitoring and IOT. 

For more information: www.oerlikon.com/fairfield

56 gearsolutions.com

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