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August 2012 C O N T E N T S IMTS 2012 COVERAGE 22 Show Preview 25 Show Listings 28 Booth Previews FEATURE 52 PM Magic Design innovations grow PM universe. TECHNICAL ARTICLES 46 Ask the Expert: Profile Shift 60 High-Performance Sintered-Steel Gears: A Critical Review A decade’s R&D of high-performance, sintered-steel gear prototyping. 66 Case Study: Surface Durability and Improved Surface Finish Super-finishing’s impact on micropitting: evaluation of gearbox/manufacturing process. 52 Vol. 29, No. 5 GEAR TECHNOLOGY, The Journal of Gear Manufacturing (ISSN 0743-6858) is published monthly, except in February, April, July and December by Randall Publications LLC, 1840 Jarvis Avenue, Elk Grove Village, IL 60007, (847) 437-6604. Cover price $7.00 U.S. Periodical postage paid at Arlington Heights, IL, and at additional mailing office (USPS No. 749-290). Randall Publications makes every effort to ensure that the processes described in GEAR TECHNOLOGY conform to sound engineering practice. Neither the authors nor the publisher can be held responsible for injuries sustained while following the procedures described. Postmaster: Send address changes to GEAR TECHNOLOGY, The Journal of Gear Manufacturing, 1840 Jarvis Avenue, Elk Grove Village, IL, 60007. Contents copyrighted ©2012 by RANDALL PUBLICATIONS LLC. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission in writing from the publisher. Contents of ads are subject to Publisher’s approval. Canadian Agreement No. 40038760. 2 GEARTECHNOLOGY August 2012 www.geartechnology.com
Customers Say it Best We are extremely satis ed with the performance, quality and exibility of our new Niles ZX 1000 gear grinder. This machine—our 10th gear grinder from Kapp-Niles—has reduced cycle and set-up times by as much as 60% compared to traditional form grinding techniques. It has allowed us to capture high-speed turbo compressor bull gears to 39 inches in pitch diameter, and to AGMA class 13 and above. Its ability to do both form grinding and generating grinding has also been a valuable asset. Once again Kapp-Niles has hit a home run with the ZX1000, and we are very happy to have them on our team. – Riley Gear, Inc. The NILES ZX 1000, and the KAPP KX 500 FLEX Gear Center, plus various grinding technologies will be at KAPP-NILES Booth N-7036 during the IMTS 2012. Come to our booth and meet our experts in hard gear finishing methods and applications. Riley Gear has manufactured precision gears and custom power transmission designs for over 66 years. The company is registered to ISO/TS 16949:2009, ISO9001:2008 and A9100C. The testimony of our customers reflects our mission. Ninety six of every one hundred KAPP and NILES machines delivered in North America since 1980 are still generating prof its for our customers today. When you purchase a KAPP or NILES machine, you get a commitment for support that does not expire. Booth N-7036 Geared to make things move. KAPP Technologies 2870 Wilderness Place Boulder, CO 80301 Phone: (303) 447-1130 Fax: (303) 447-1131 www.kapp-usa.com info@kapp-usa.com
Page 1 and 2: August 2012 ® www.geartechnology.c
Page 3: Plan to see us at IMTS! http://info
Page 7 and 8: Think Big! Grind Big! IMTS CHICAGO
Page 10 and 11: Our Technologies, Your Tommorow The
Page 12 and 13: V O I C E S Adapting Lean for High-
Page 14 and 15: V O I C E S Figure 1—Material Flo
Page 16 and 17: P R O D U C T N E W S New Technolog
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Page 20 and 21: P R O D U C T Dudley’s Handbook o
Page 22 and 23: P R O D U C T SKF Stroboscope Facil
Page 24 and 25: IMTS North America’s Show of Show
Page 26 and 27: iting companies want stationed on t
Page 28 and 29: IMTS 2012 Alphabetical Listings COM
Page 30 and 31: IMTS 2012 Product Preview Star SU B
Page 32 and 33: MAG H 400: Run small lots or mass p
Page 34 and 35: Kapp Technologies Booth N-7036 Two
Page 36 and 37: different grinding wheels in one se
Page 38 and 39: able for the machining of workpiece
Page 40 and 41: See Drake’s newest External Threa
Page 42 and 43: evel breakthrough See the gleason-h
Page 44 and 45: More Than Machines, • BMS Electro
Page 46 and 47: BRIGHT IDEAS, BRILLIANT SOLUTIONS A
Page 48 and 49: A S K T H E E X P E R T Got a Gear
Page 50 and 51: A S K T H E E X P E R T profile shi
Page 52 and 53: A S K T H E E X P E R T external ge
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Powder Metal Magic Design Innovatio
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This helical/spur combination gear
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of tooth geometry control along wit
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Foreground: Medical introducer part
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High-Performance Sintered-Steel Gea
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Figure 3—Rolling contact fatigue
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tance, a surface-densification tech
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Case Study Involving Surface Durabi
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Figure 4—Baseline Gear A, Mesh 1,
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Table 3—Roughness parameters of b
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Figure 17—ISF Gear A, Mesh 1: pos
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Table 9—Design requirements for I
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N E W S In Memoriam James J. Cervin
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N E W S In her new role, Codina is
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N E W S Sunnen Receives Global Pion
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MFN is Official Cooperation Partner
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C A L E N D A R September 10-15—I
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A D V E R T I S E R S i n d e x ADV
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A D D E N D U M Technology Mash-Up
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HÖFLER by KLINGELNBERG: Gear Hobbi
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