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I. On-mach<strong>in</strong>e dress<strong>in</strong>g <strong>in</strong>tegrate<br />
<strong>the</strong> dre s<strong>in</strong>g unit with <strong>the</strong> gr<strong>in</strong>d<strong>in</strong>g<br />
head to ensure <strong>the</strong> highest level of<br />
repeatability. Compensation for<br />
wheel wear between dresses is<br />
automatic .<br />
• Designed with <strong>the</strong> flexib.ility Ito<br />
al 0 gr<strong>in</strong>d <strong>in</strong>ternal and external!<br />
gears with non-dressable Gleason<br />
high-precision vitrified or plated<br />
CBN wheels .<br />
• On-mach<strong>in</strong>e <strong>in</strong>spection analyzes<br />
stock distribution. and compensates<br />
for heat treat distortion and pari.<br />
runout. The gr<strong>in</strong>d<strong>in</strong>g cycle is optimized<br />
automatically.<br />
The bigger <strong>the</strong> gr<strong>in</strong>d<strong>in</strong>g application, <strong>the</strong>beuer we look. From 400<br />
to 4,000 mm Gleason-Pfauter Profile Gr<strong>in</strong>ders can take <strong>the</strong> lime.<br />
cost and question marks out of your process, and put more<br />
profitability <strong>in</strong>.<br />
I. Gr<strong>in</strong>d<strong>in</strong>g technology database recommends and<br />
optimizes <strong>the</strong> "perfect production" methodology.<br />
• K-Chart <strong>in</strong>spection allows specific <strong>in</strong>put<br />
for both profile<br />
and lead modifications.<br />
I. Tooth twi t compensation for noise-controland<br />
high performance application corrects tooth<br />
profile deviations.<br />
Call us. We 11cut your big gr<strong>in</strong>d<strong>in</strong>g challenges down to size.<br />
1000 University Ave., P.O..Box 22970<br />
Rochester, NY 14692-2970 U.S.A.<br />
Phone: 5&5/473-1()(X) Fax: 585/4614348<br />
Web site: www.gleason.com E-mail: salestsgleason.com<br />
Gleason delivers <strong>the</strong> pDwer. IMrS '02 - BDD'th # 6931
JULV/AUGUST <strong>2002</strong> I The Journal of <strong>Gear</strong> Manufactur<strong>in</strong>g _<br />
FEATURES<br />
26<br />
IMTS <strong>2002</strong> SPECIAL SE,CTION<br />
<strong>Gear</strong> Surface D'uralbility Devel:opment to iEnhance!<br />
Transmissiion Power Density<br />
Experiments to <strong>in</strong>crease pitt<strong>in</strong>g resistance <strong>in</strong> auto transmission gears 20<br />
Performancel A_na'lysisof H;ypoid <strong>Gear</strong>s bvTooth ,Flank Form Measurement<br />
Detailed measur<strong>in</strong>g of hypoid gears by scann<strong>in</strong>g mach<strong>in</strong>e 26<br />
M<strong>in</strong>imizat;ion of ln-Pmeess Co,rrosiohl of Aerospa,ce <strong>Gear</strong>s<br />
Experiments to reduce corrosion of gears dur<strong>in</strong>g production 36<br />
<strong>2002</strong> FAQs,and Pavilion Info , , 12<br />
<strong>2002</strong> Show Indicat'8s M<strong>in</strong>imal Recession Damalge<br />
Expected IM:TS attendance 16<br />
DEPARTMENTS<br />
12,<br />
Allon - with <strong>the</strong> Show<br />
- 9 - --<br />
A technical conference, student participation<br />
and attractions outside <strong>the</strong> show 18<br />
9<br />
Publisher's Page<br />
The E-volution of <strong>Gear</strong> Technology 7<br />
iRevolutions<br />
Edw<strong>in</strong> R..Fellows and a very large gear unit. '9<br />
I<strong>in</strong>dustry News<br />
What's happen<strong>in</strong>g <strong>in</strong> <strong>the</strong> gear <strong>in</strong>dustry .., 32<br />
Technicall Calendar<br />
Don't miss <strong>the</strong>se important upcom<strong>in</strong>g 'events 34<br />
P,roduct N!ews<br />
'The latest products for <strong>the</strong> gear <strong>in</strong>dustry 44<br />
.Advertiser Index<br />
NEW! Phone numbers and web addresses to make it easier to get <strong>in</strong><strong>format</strong>ion 49,<br />
Classifi.eds<br />
Services. Help Wanted and more 50<br />
__ ----" 52, ,Addendum<br />
A <strong>Gear</strong> With A Sweet Tooth , , , , , ..'1;2,
I~ur S.400 GT <strong>Gear</strong> Gr<strong>in</strong>d<strong>in</strong>g Mach<strong>in</strong>e<br />
IS flexible and' easy to usa I,t allows<br />
you to employ or even comb<strong>in</strong>e<br />
different gr<strong>in</strong>d<strong>in</strong>g technologies liike<br />
profile, gr<strong>in</strong>d<strong>in</strong>g, cont<strong>in</strong>uous 'generat<strong>in</strong>g<br />
gr<strong>in</strong>d<strong>in</strong>g, shave gr<strong>in</strong>d<strong>in</strong>g (external<br />
hon<strong>in</strong>g) to f<strong>in</strong>d <strong>the</strong> most efficient way<br />
to gr,<strong>in</strong>d your g.ear, worm or rotor.<br />
Fully equipped with today's standard,<br />
like l<strong>in</strong>ear motor technology and GNG,<br />
<strong>the</strong> S 400 GTaJlows for <strong>the</strong> adapl.ation<br />
of <strong>the</strong> latest tool developments -<br />
which proba.bly makes it today's most<br />
versatile gr<strong>in</strong>d<strong>in</strong>g mach<strong>in</strong>e.<br />
In addition, we provide you with G8N<br />
and electroplated gr<strong>in</strong>d<strong>in</strong>g wheels and<br />
worms Ibased on our I'onglexperience<br />
as at developer of gr<strong>in</strong>d<strong>in</strong>g technology.<br />
Contact us for <strong>the</strong> latest <strong>in</strong><br />
gr<strong>in</strong>d<strong>in</strong>g technology.<br />
SU America l<strong>in</strong>c.<br />
5200 Prairie Stone Parkway,<br />
Suite 100<br />
H'offman Estates, IL 60192<br />
Tel.: 847 649-1450<br />
Fax: 847 649-01' 112<br />
E-mail: sales@suamerica.com<br />
http://www.suameriica.com<br />
_....-<br />
Hobb<strong>in</strong>g' - Profile Gr<strong>in</strong>d<strong>in</strong>g - Generat<strong>in</strong>g Gr<strong>in</strong>d<strong>in</strong>g - Shave Gr<strong>in</strong>d<strong>in</strong>g - Chamfer<strong>in</strong>g - 'Deburr<strong>in</strong>g - Shav<strong>in</strong>g! Culter Gr<strong>in</strong>d<strong>in</strong>g<br />
Bevel <strong>Gear</strong> Cutt<strong>in</strong>g - Tool and Commodity Management Services (eMS)
I<br />
GEAR TECHNOLOGY<br />
,EDITORIAL<br />
Publisher '& F.dito ..-iD-Chi~f<br />
Michael Goldste<strong>in</strong><br />
Manag<strong>in</strong>g Editor WiUiam R. Stoll<br />
Associate Editor Joseph L Huzelton<br />
Assistant. .Edilor Rob<strong>in</strong> Wright<br />
Editorial Consultant Paul R. Goldste<strong>in</strong><br />
Technical Editors<br />
Robert Errichello<br />
Don McVittie<br />
Robert E. Smith<br />
Dun Thurman<br />
ARI<br />
Art Director Jean Bartz<br />
Ultra Predse Hobs<br />
Accuracy Class: AAA, M, A<br />
Materials:. Carbide/Bridge/HSS<br />
•<br />
Techno[ogy, Dry/High Speed/Hard Hobb<strong>in</strong>g<br />
Range: 10 - SOO Diametral !Pitch<br />
STOCKAVAILABLE<br />
Visit<br />
itUSSELL.<br />
HOLBROOK&<br />
HENIDERSON.IINC.<br />
17~1i' -Route 208 North, Fair Lawn. New jer:s.eyO'7"'.'lD<br />
T@lephone:201-796-51145 Fax: 201-796·S664<br />
"'~'iE1hEIUt:i~'IIIq,a.,t;,'ltA..'IF'<br />
our website at: http://www.tru-volule.com<br />
Advertis<strong>in</strong>g Manager Patricia Flam<br />
Adv~g Coord<strong>in</strong>ator Angel ica Vi loria<br />
CIRCIJLATI(IN<br />
Circulation Coord<strong>in</strong>ators<br />
D<strong>in</strong>a Krauss & Angelica Viloria<br />
Web Developer<br />
INTE.IINEl<br />
Dan MacKenzie<br />
<strong>Gear</strong> Indllstry Home Pagel M Sales<br />
Patricia Ram<br />
powertransmission.com TM Sales<br />
Michael A. Gianfrancesco<br />
!lANDAU PUBLISHING STAff<br />
President<br />
Vice President<br />
Controller<br />
Accountln/.:<br />
omce Coord<strong>in</strong>ator<br />
Michael Goldste<strong>in</strong><br />
Richard Goldste<strong>in</strong><br />
Michael Grafman<br />
Dianne Johnson<br />
Gladyce J. Cooper<br />
Phone: 847437.661)4<br />
E-mail: people@gear:lecll1lofiJgy.com<br />
Web: www.geartechnology.com<br />
www.powertransmission.com<br />
capaI_,1ncIud1ng tInII8 element.<br />
Arrow's latest success was utmztng our<br />
s1ate-of-1he-art technologies to design <strong>the</strong><br />
gear t001h geometry and to manufacture<br />
all bevel gears <strong>in</strong> 1he PT1l & AGB for<br />
Pratt & Whitney's PW 6000 eng<strong>in</strong>e.<br />
2301 Curtiss Street· Downers Grove, IL 60515<br />
Tel: (630) 969-7640 • Fax: (630) 969-0253<br />
www.arrowgear.com<br />
VOL 119,NO.4<br />
GF:,\R TEeIlNOL!) .y, l'b. Journal or ce ..<br />
I\lu""raclurlng (lSSN 07-13-6858) ls published bimonthly<br />
by Rundall Publish<strong>in</strong>g. Inc .. 1425 Lun: Avenue. PO. Bo.<br />
1426, Elk Grove village. IL 60007. (847) 437·6bQ.I. Cover<br />
price 55.00 U.S_ Periodical postage puid 01 Arl<strong>in</strong>g'a.<br />
Heigh". IL. end at addi[ional mail<strong>in</strong>g offic e, Randall<br />
Pubhsh<strong>in</strong>g makes e ..·cry effort 10 ensure that <strong>the</strong> processes<br />
do,,'libed 'n GEAR TECHNOLOGY conform 10"",ad engane;:rm~<br />
practice. Nei<strong>the</strong>r <strong>the</strong> umbers 1lIJT <strong>the</strong> pubhsber can be<br />
held respcnn ble for <strong>in</strong>juries susralned while follow<strong>in</strong>g <strong>the</strong><br />
procedures described. Postmaster: Send uddress cbunges 10<br />
GEAR TECHNOLOGY. The Journal of <strong>Gear</strong><br />
Manufncturf ng. 1425 Lum Avenue, P.O. Bu. L426. Elk<br />
Oro"< Village. IL. 60001. OConl.nts ropyriglllL-d by RAN·<br />
DA.LL Pl'BLISHlNG. [NC.. <strong>2002</strong>. No pen of lh" publica-<br />
[ion ma) be reprod ueed or uansmmed <strong>in</strong> an) form or by an)<br />
mCQn~: electronic Or mechanleuj. <strong>in</strong>dud<strong>in</strong>gthou:-cop) <strong>in</strong>g,<br />
record<strong>in</strong>g, or by any <strong>in</strong>formauon storage an rerneval system.<br />
wuhour permission <strong>in</strong> wri{<strong>in</strong>g from [he publisher.<br />
Contents or ud:-i
MACHINE<br />
Up To<br />
MORE PARTS<br />
PER HOUR.<br />
Dura-Bar Plus is a new eng<strong>in</strong>eered iron<br />
that mach<strong>in</strong>es better than carbon and alloy<br />
steels ... and better than competitive grades of<br />
cont<strong>in</strong>uous cast iron.<br />
New & Improved Dura-Bar Plus gives you<br />
A LOWER ,CO TPERPART •••<br />
PLiUS - MORE PART PER HOURI<br />
Decrease cycle time.<br />
Increase productivity!<br />
PLUS - LONGER INSERT LIFE!<br />
Reduce your downtime for<br />
tool<strong>in</strong>g change !<br />
PLUS - A DEFEO-FREE<br />
Quality guaranteed!<br />
MATERIAL!<br />
Dura-Bar Plus is available <strong>in</strong> gray and ductile<br />
iron grades and <strong>in</strong> a wide variety of sizes<br />
and shapes. For more <strong>in</strong><strong>format</strong>ion. sec<br />
web site at www.dura-bar.com.<br />
Or call<br />
I-SOD-BAR MILL<br />
(1-800-227 -6455)<br />
INCREASE "0 R MJ\ClDNlNG<br />
PRODUcrWITI' A~D S.4\'[ MONEl' wrrn<br />
New Dura-Bar Plus, THE LATEST<br />
I ENGlNiELRJD l\1ETA~TECHNOLOGl'.<br />
Cont<strong>in</strong>uous<br />
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E-mail: sa'les@dura-bar.com Internet: www.dura-bar.com
LMT-.FEITE end L.I.EBHERR'<br />
for gear cutt<strong>in</strong>g otutions ..<br />
LMT-F,ETT:E'slegendary cra,ftsmanship and precision ha,ve<br />
earned us a world-wide reputation for produc<strong>in</strong>g hobs thallarle<br />
unsurpassed <strong>in</strong> <strong>the</strong> 'gear <strong>in</strong>dustry. Now we .r'oudl announce<br />
a newpafitnership, l<strong>in</strong> <strong>the</strong> North Amedcan market with<br />
LIIEiBHIERiR.<strong>the</strong> <strong>in</strong>dustry leader of LORENZ®$;hap<strong>in</strong>g. shav<strong>in</strong>g:<br />
and ,gaug<strong>in</strong>g tools" By comb<strong>in</strong><strong>in</strong>g <strong>the</strong> strengths of <strong>the</strong>se global!<br />
leaders, weare now North America,'ss<strong>in</strong>gle-.source so!lutionl<br />
provider <strong>in</strong> <strong>the</strong> gear <strong>in</strong>dustry.<br />
'Comb<strong>in</strong><strong>in</strong>g premium materials, st·alte-of-<strong>the</strong>-a,rt coa't<strong>in</strong>gs<br />
and <strong>the</strong> most advanced heat-Irealt<strong>in</strong>g processes, we prlovide<br />
gear cutt<strong>in</strong>gl tools that out-per1orm all o<strong>the</strong>rs. Our cont<strong>in</strong>uall<br />
<strong>in</strong>vestment <strong>in</strong> research and deve'lopment ensures each LMT:.<br />
FETTE and LORENZ® product is designed alnd built toexceedl<br />
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All LMT-FETTE and LIE'BHiE'R:R'gear ,cutl<strong>in</strong>g tools<br />
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Solid HSS Hobs<br />
Sol:id Carbide Hobs<br />
Multi-Gash Hobs<br />
Heavy Duty Rough<strong>in</strong>g Hobs<br />
Inde.xable Carbide Insert Rough<strong>in</strong>g IHobs<br />
Milli<strong>in</strong>g Cutters with Carbide Inserts<br />
Skiv<strong>in</strong>g Hobs<br />
Hobs for Worms, Sprockets, Rotors,<br />
Tim<strong>in</strong>g: Belt Pulleys & _ ...<br />
ShapeI' Cutters<br />
Form Mill<strong>in</strong>g Cutters<br />
Shav<strong>in</strong>g Tbols<br />
Rack TY1>eCutt.ers<br />
Roll<strong>in</strong>g Dies<br />
Roll<strong>in</strong>g Racks<br />
Broach R<strong>in</strong>gs<br />
Master <strong>Gear</strong>s<br />
Al<strong>in</strong>g and Plug Gauges<br />
Cutter .Adapters<br />
C.lamp<strong>in</strong>g Arbors<br />
C:lamp<strong>in</strong>g Fixtures<br />
Call our new <strong>Gear</strong> Solution Center<br />
<strong>in</strong> Sal<strong>in</strong>e, Michigan at 734-429-2095<br />
1;0' t<strong>in</strong>douf how we can be your<br />
s<strong>in</strong>gle~source solution provider.<br />
18013 Cleveland<br />
r<br />
LMT •- F'ETTE<br />
,./<br />
Cleveland Ohio 44135
-------- -<br />
PUBUS,HER'S, PAGE<br />
_<br />
The E-volution of<br />
<strong>Gear</strong> Technology<br />
Technology creates excitement. lust consider <strong>the</strong> natural<br />
buzz around IMTS, where manufacturers will go to explore<br />
ways <strong>the</strong>y can <strong>in</strong>crease productivity. improve quality, decrease<br />
costs or provide better service.<br />
But technology is not just for manufacturers. At <strong>Gear</strong><br />
Technology, we're creat<strong>in</strong>g a buzz of OUT own. That buzz is over<br />
E·G! <strong>the</strong> next phase <strong>in</strong> OUl" technological evolutlon. E-GT<br />
stands for Electronic <strong>Gear</strong> Technology. II's one of <strong>the</strong> biggest<br />
changes we've made <strong>in</strong> ]8 years, and it's go<strong>in</strong>g to make access<br />
10 <strong>Gear</strong> Technology's <strong>in</strong><strong>format</strong>ion easier than ever before.<br />
Beg<strong>in</strong>n<strong>in</strong>g with <strong>the</strong> January/February 2003 issue, <strong>the</strong> entire COI1-<br />
tents of <strong>the</strong> magaz<strong>in</strong>e will be available electronically. That<br />
<strong>in</strong>cludes all <strong>the</strong> articles, all <strong>the</strong> advertisements. all <strong>the</strong> figures<br />
and formulas, exactly as <strong>the</strong>y appear <strong>in</strong> <strong>the</strong> pr<strong>in</strong>t version.<br />
Of course, we're not chang<strong>in</strong>g <strong>the</strong> pr<strong>in</strong>ted magaz<strong>in</strong>e. The regular<br />
version of <strong>Gear</strong> Technology will cont<strong>in</strong>ue to be available to<br />
all our qualified U.S. readers=-for free-just as it always has.<br />
Also, people outside <strong>the</strong> United States will still be able to purchase<br />
subscriptions \0 <strong>the</strong> pr<strong>in</strong>ted version.<br />
Pan of what makes E-GTexcit<strong>in</strong>g is that we're do<strong>in</strong>g someth<strong>in</strong>g<br />
thai very few o<strong>the</strong>r magaz<strong>in</strong>es are able or will<strong>in</strong>g to do.<br />
While we've always brought you <strong>in</strong><strong>format</strong>ion on lead<strong>in</strong>g edge<br />
technology related to gear manufactur<strong>in</strong>g, E-GT keeps us on <strong>the</strong><br />
lead<strong>in</strong>g edge ourselves. I'm proud of thai capability. But what's<br />
really excit<strong>in</strong>g about E-GT is how it will enable us to better<br />
serve our <strong>in</strong>dustry.<br />
E-GT means that qualified subscribers wiU have access (Q an<br />
exact copy of our magaz<strong>in</strong>e {<strong>in</strong> .<strong>PDF</strong> <strong>format</strong>) via The <strong>Gear</strong><br />
Irtdrlstry Home PageThI. You'll be able 10 retrieve an electronic<br />
version of <strong>the</strong> current i sue whenever you want. You'll be able<br />
to store it on your hard drive to create an archive of issues for<br />
easy reference. And you'll, be able to search through a particular<br />
issue for keywords or company names. You'll be able to receive<br />
E-GT when you're travel<strong>in</strong>g. You'll be able to carry it on your<br />
laptop or bum it onto a CD.<br />
S<strong>in</strong>ce we began publish<strong>in</strong>g <strong>Gear</strong> Technolog), <strong>in</strong> 1984, our<br />
mission has been to serve <strong>the</strong> gear <strong>in</strong>dustry with <strong>the</strong> best possible<br />
technical and educational <strong>in</strong><strong>format</strong>ion related to <strong>the</strong> design,<br />
process<strong>in</strong>g, manufactur<strong>in</strong>g and <strong>in</strong>spection of gears. Today, our<br />
mission is <strong>the</strong> same ..E-GT makes it easier for LIS to carry it out.<br />
For example, wilth each pass<strong>in</strong>g year, <strong>the</strong> gear <strong>in</strong>dustry has<br />
become more global. Until now. we've had to charge subscribers<br />
outside <strong>the</strong> United States to offset <strong>the</strong> substantial costs of mail<strong>in</strong>g<br />
<strong>the</strong> magaz<strong>in</strong>e. E-GTelim<strong>in</strong>ales those costs, It will be available<br />
for free to qualified subscribers anywhere <strong>in</strong> <strong>the</strong> world.<br />
Ano<strong>the</strong>r benefit for subscribers outside <strong>the</strong> United Stales is<br />
that <strong>the</strong>y' II no longer have to wait two or more weeks extra 10<br />
receive <strong>the</strong>ir issues by mail. They'll have access to <strong>the</strong> content<br />
as soon as <strong>the</strong> issue is published and <strong>the</strong> electronic version is<br />
uploaded<br />
to our website.<br />
To ensure that our magaz<strong>in</strong>e is reach<strong>in</strong>g <strong>the</strong> right audience,<br />
our electronic subscribers will fill out .1 qualification card once<br />
per year, just as <strong>the</strong>y do with our pr<strong>in</strong>ted version. Part of that<br />
qualification card will <strong>in</strong>clude <strong>the</strong> subscriber's e-mail address.<br />
When each issue becomes available onl<strong>in</strong>e, we'll e-mail <strong>the</strong><br />
subscribers a notice to I.e! <strong>the</strong>m know <strong>the</strong>y can download <strong>the</strong><br />
issue at <strong>the</strong>ir convenience.<br />
£-GTis a cont<strong>in</strong>uation of <strong>the</strong> process we began <strong>in</strong> 1996. with<br />
<strong>the</strong> launch<strong>in</strong>g of The <strong>Gear</strong> Industry Home Pag,e, which<br />
rema<strong>in</strong>s <strong>the</strong> Internet's premier marketplace for <strong>the</strong> mach<strong>in</strong>ery,<br />
cutt<strong>in</strong>g tools and services<br />
related to gear manufactur<strong>in</strong>g.<br />
In 1.997, we launched<br />
powertraIJSlllissioll.c.om<br />
to serve as a portal for manufacturers<br />
and buyers of<br />
gears,<br />
gear dri ves and o<strong>the</strong>r<br />
power transmission components,<br />
Today, those two<br />
websites deliver more than<br />
200,000 page views and<br />
50,000 user sessions per<br />
month. They've grown, evolved and taken all. a life of <strong>the</strong>ir<br />
own, becom<strong>in</strong>g an everyday pan of <strong>the</strong> fabric of <strong>the</strong> <strong>in</strong>dustry. I<br />
expect<br />
E-GT to do <strong>the</strong> same.<br />
Michael Goldste<strong>in</strong>.<br />
Publisher<br />
& Editor-ill-Chief<br />
P.S. Those of you who Ire <strong>in</strong>terested <strong>in</strong> becom<strong>in</strong>g E-G1 subscribers<br />
cln now log on to Th. Go"IffIUIfIy H"",. I'Ige'" Ind fill out tile<br />
simple qualificetion form. Visit www.ge.ltIChnDlogy.com and<br />
look for <strong>the</strong> E-G1button. We're <strong>in</strong>terested <strong>in</strong> your commenllibout<br />
how E-G1 and our o<strong>the</strong>r prodIcts can .ate you more tfftctive Ind<br />
successful. Whl' ide .. do yoI have that WI hlven't thought of yet?<br />
Let us hear from you .. pBOplt41ge,ltIChnology.cDfll.<br />
wWIW.powerfransmluion.com· WWW.gearlechnology.com • GEAR TECHNOLOGY· JULV/AUGUST <strong>2002</strong> 7
Produc,tivity ls synonyml'ous with<br />
Kll<strong>in</strong>g,el:n,be,rg-,Oe'rlikon.<br />
Our vision is <strong>the</strong> longlerm tech:nological palnnersh:ip'<br />
wiithl o'ur cu'siomers.<br />
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REVOLUnONS<br />
Edw,<strong>in</strong> IR.IFeliows:<br />
Sh,api<strong>in</strong>g <strong>the</strong> O,ear -Industry<br />
On <strong>July</strong> 13, 1896, a former w<strong>in</strong>dow<br />
dresser received a $5.000 budget to start<br />
a company for mak<strong>in</strong>g his far-reach<strong>in</strong>g<br />
<strong>in</strong>vention: <strong>the</strong> gear shaper mach<strong>in</strong>e.<br />
The former w<strong>in</strong>dow dresser was<br />
Edw<strong>in</strong> R. Fellows from Torr<strong>in</strong>gton, CT.<br />
The money was from subscribers (read:<br />
venture capitali ts). And his <strong>in</strong>vention<br />
was an idea he worked<br />
on while a draftsman<br />
at Jones & Lam on Mach<strong>in</strong>e Co. <strong>in</strong><br />
Spr<strong>in</strong>gfield.<br />
VT.<br />
In 1916, <strong>the</strong> Fellows <strong>Gear</strong> Shaper Co.<br />
reached $1 million <strong>in</strong> mach<strong>in</strong>ery sales<br />
for <strong>the</strong> first lime. The bus<strong>in</strong>ess that<br />
became Fellows Corp. was on its way.<br />
By <strong>the</strong>n, Fellows was a director of his<br />
company.<br />
In 1896, though, he was its 31-yearold<br />
manager, with a workforce of seven<br />
people. His first gear shape]" mach<strong>in</strong>e<br />
was completed <strong>in</strong> 1897 ,though an experimental<br />
version had been built <strong>in</strong> 1896, at<br />
a mach<strong>in</strong>e shop <strong>in</strong> Fitchburg MA.<br />
Fellows' mach<strong>in</strong>e <strong>in</strong>troduced a new<br />
type of gear-cull<strong>in</strong>g tool. His shaper cut-<br />
ter was a. hardened, ground gear with<br />
sharpened teeth.<br />
"At that time, no one else was mak<strong>in</strong>g<br />
gear (shaper) cutters," says Don<br />
Whitney. a former manager of Fellows<br />
Corp. 's cutter-eng<strong>in</strong>eer<strong>in</strong>g<br />
department.<br />
By 1905, Fellows' company was<br />
already hav<strong>in</strong>g an impact on <strong>the</strong> automobile<br />
<strong>in</strong>dustry. That impact is reflected <strong>in</strong><br />
Precision Valley, an account of <strong>the</strong><br />
mach<strong>in</strong>e-tool <strong>in</strong>dustry that developed <strong>in</strong><br />
<strong>the</strong> valley where Spr<strong>in</strong>gfield is located.<br />
The book lists automobile manufacturers<br />
that were Fellows customers <strong>in</strong><br />
1905. Those manufacturers <strong>in</strong>cluded<br />
Buick Motor Co., Packard Motor Car<br />
Co., Olds Motor Works" Dodge<br />
Bro<strong>the</strong>rs,<br />
Cadillac Motor Car Co., and Pierce-<br />
Arrow Motor Car Co.<br />
Before his company's start, though.<br />
Fellows got his start <strong>in</strong> Spr<strong>in</strong>gfield with<br />
<strong>the</strong> help of a mend, James Hartness.<br />
Hartness is remembered as a prom<strong>in</strong>ent<br />
Vermont <strong>in</strong>dustrialist and public figure.<br />
He is credited with 12() patents,<br />
rang<strong>in</strong>g from <strong>the</strong> flat turret la<strong>the</strong> to a<br />
safety razor. Irt 1900, he became president<br />
of Jones & Lamson. In 1921, he<br />
became Vermont's governor.<br />
In 1889, though, Hartness was an<br />
employee at Jones & Lamson and was<br />
urg<strong>in</strong>g his Connecticut<br />
friend to jo<strong>in</strong> him.<br />
Fellows did so and became a Jones &<br />
Lamson employee <strong>in</strong> 1.889..<br />
The future <strong>in</strong>dustrialists knew each<br />
o<strong>the</strong>r through Fellows' mo<strong>the</strong>r.<br />
Years eartier, Fellows' fa<strong>the</strong>r bad died<br />
while Fellows was <strong>in</strong> high school.<br />
Afterward, Fellows' mo<strong>the</strong>r took <strong>in</strong><br />
boarders.<br />
"Young Hartness was one of <strong>the</strong><br />
boarders," Whitney says. "He and Edw<strong>in</strong><br />
personal curiosity. For a time, Whitney<br />
taught a cutter design course at Fellows<br />
Corp., so he researched <strong>the</strong> company's<br />
history to create a preface for <strong>the</strong> booklet<br />
used <strong>in</strong> <strong>the</strong> course.<br />
As for his personalcuriosity <strong>the</strong> 45-<br />
year employee of Fellows Corp. say :<br />
"I'm naturally <strong>in</strong>terested <strong>in</strong> it becau e<br />
that was my life,"<br />
Fellows' <strong>in</strong>vention received public<br />
recognition just a few years after his<br />
company's start.<br />
In 1899. Fellows received <strong>the</strong> John<br />
Scott Award from <strong>the</strong> city of Philadelphia<br />
for his gear shaper mach<strong>in</strong>e and cutter.<br />
The award is given to men and<br />
women whose <strong>in</strong>ventions contribute :<strong>in</strong><br />
outstand<strong>in</strong>g ways to people's comfort.<br />
welfare and happ<strong>in</strong>ess. O<strong>the</strong>r recipients<br />
of <strong>the</strong> award <strong>in</strong>clude Marie Curie,<br />
Thomas Edison, Jonas Salk and Orville<br />
and Wilbur<br />
a significant advance <strong>in</strong> gear manufac-<br />
were good friends."<br />
tur<strong>in</strong>g.<br />
Edw<strong>in</strong> R. If,ellows: Thill tonner w<strong>in</strong>dow dresser<br />
mad'e ,good as, <strong>the</strong> <strong>in</strong>ventor of tbe' gear sbaper<br />
Whi.tney knows about Fellows and his Also, Fellows' gear shaper could<br />
mach<strong>in</strong>e.<br />
company from work-related research and make "shoulder gears," two differentwww.pow6r/ransmlsslon.com·'<br />
www.g6artachnology.com· GEAR TECHNOLOGY' JULY/AUGUST <strong>2002</strong> 9<br />
Wright.<br />
Fellows' mach<strong>in</strong>e made gears by simulat<strong>in</strong>g<br />
<strong>the</strong> mesh<strong>in</strong>g of two gears rotat<strong>in</strong>g<br />
around two parallel axes, A gear blank<br />
would be mounted on a vertical arbor. A<br />
complete gear, <strong>the</strong> cutter would. <strong>the</strong>n<br />
move up and down as it and <strong>the</strong> blank<br />
slowly revolved synchronously.<br />
As Whitney expla<strong>in</strong>s, one cutter<br />
could produce spur and. helical gear of<br />
any size, with any number of teethwhe<strong>the</strong>r<br />
<strong>the</strong>y were external or <strong>in</strong>ternal<br />
gears. L.T.C. Holt, though. notes a<br />
restriction<br />
<strong>in</strong> his book A Shorr History of<br />
Mach<strong>in</strong>e Tools: Fellows' cutter could<br />
make different-sized gears so long as<br />
<strong>the</strong>ir pitches were <strong>the</strong> same and <strong>the</strong><br />
gears'<br />
was made<br />
teeth had <strong>the</strong> helix angle <strong>the</strong> cutter<br />
to create.<br />
Whitney says that ability represented
sized gears on <strong>the</strong> same shaft with little<br />
clearance between <strong>the</strong>m. That ability<br />
permitted more compact design of automobile<br />
transmissions.<br />
In Holt's op<strong>in</strong>ion, though, Fellows'<br />
cutter-gr<strong>in</strong>d<strong>in</strong>g mach<strong>in</strong>e was more significant<br />
than his gear shaper mach<strong>in</strong>e. He<br />
expla<strong>in</strong>s that Fellows' precision gr<strong>in</strong>di ng<br />
mach<strong>in</strong>e foreshadowed <strong>the</strong> gr<strong>in</strong>d<strong>in</strong>g of<br />
hardened gears as a common step <strong>in</strong> production.<br />
Fellows worked for his company for<br />
<strong>the</strong> rest of his life. He was president and<br />
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REVOLUTIONS<br />
director when he died May 21, 1945.<br />
Fellows Corp. cont<strong>in</strong>ued to serve gear<br />
manufacturers for ano<strong>the</strong>r 57 years. It<br />
stopped operations Feb. 13, its parent<br />
company fil<strong>in</strong>g for bankruptcy.<br />
On May 23, BF Acquisition won its<br />
bid for Fellows Corp. BF Acquisition is<br />
an affiliate of Park Corp., an Ohio-based<br />
company.<br />
As reported <strong>in</strong> <strong>the</strong> Rutland' Herald of<br />
Rutland, VT, BF Acquisition bid $3.72<br />
million for <strong>the</strong> company.<br />
BF Acquisition's purchase was<br />
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A Two~Story<strong>Gear</strong> Unit<br />
BHS-C<strong>in</strong>c<strong>in</strong>nati Getriebetechnik GmbH<br />
of Sonthofen, Germany, recently delivered<br />
what it says is <strong>the</strong> world's large t<br />
<strong>in</strong>tegral gear unit at more than 5 meters<br />
wide, more than 4.5 meters tall and<br />
weigh<strong>in</strong>g more than 42 tons. The gear<br />
unit was sold to MA<br />
; Turbomasch<strong>in</strong>en<br />
AG, GHH Borsig, of Berl<strong>in</strong>. a German<br />
compressor manufacturer.<br />
MAN Turbomasch<strong>in</strong>en' eu tomer, a<br />
Ch<strong>in</strong>ese chemical plant. plans to use this<br />
gear unit for manufactur<strong>in</strong>g purefied<br />
terephthalic acid (PTA), a material used<br />
<strong>in</strong> polyester fiber production.<br />
What's unique about <strong>the</strong>se large <strong>in</strong>tegral<br />
gear units is that <strong>the</strong> compressor is<br />
not mounted <strong>in</strong> l<strong>in</strong>e with <strong>the</strong> gear drive<br />
but is directly mounted to <strong>the</strong> gear cas<strong>in</strong>g.<br />
says BHS eng<strong>in</strong>eer<strong>in</strong>g sales manager<br />
Stefan Burkart. With this arrangement,<strong>the</strong><br />
efficiency rate can be significantly<br />
improved and <strong>the</strong> space requirement<br />
significantly reduced versus traditional<br />
stand-alone units,<br />
O<strong>the</strong>r companies make this k<strong>in</strong>d of<br />
device, but this one is larger than most.<br />
However. similar sized <strong>in</strong>tegral gear<br />
units are sold by Flender Corp. of<br />
Bochoh, Germany •.and SMS Dernag AG<br />
of Dusseldorf,<br />
Germany,<br />
The primary advantage of <strong>the</strong> <strong>in</strong>tegral<br />
gear unit is <strong>the</strong> compact <strong>in</strong>stajlauon it<br />
provides through <strong>the</strong> elim<strong>in</strong>ation of <strong>the</strong><br />
coupl<strong>in</strong>g along w.ith <strong>the</strong> capability of<br />
mount<strong>in</strong>g <strong>the</strong> compressor hous<strong>in</strong>g<br />
directly to <strong>the</strong> gearbox, says Patrick<br />
Potter, sales eng<strong>in</strong>eer at BHS-C<strong>in</strong>c<strong>in</strong>nali<br />
Even for s<strong>in</strong>gle-p<strong>in</strong>ion units, this i a ignificant<br />
advantage because <strong>the</strong> compressor<br />
hous<strong>in</strong>g can be overhung from <strong>the</strong><br />
skid. which allows much more flexibility<br />
<strong>in</strong> pip<strong>in</strong>g arrangements for <strong>the</strong> compressor's<br />
process ga ,<br />
For multiple-p<strong>in</strong>ion units, <strong>the</strong> ability<br />
to mount <strong>the</strong> compressor cas<strong>in</strong>gs directly<br />
~Q <strong>the</strong> gearbox is a technical and co t<br />
advantage because multiple stages of
1 -------<br />
.. REVOLUTilONS<br />
:Stand<strong>in</strong>g talll at '4.5metllrs and weighillg <strong>in</strong> at ,4,2<br />
tons, 'this <strong>in</strong>tegral g,ear unit hom BHS·'C<strong>in</strong>c<strong>in</strong>nati<br />
'l.ieuiebetech~k Gmb'lI ,ofSaniliofeu'. Gellllan-y. is<br />
(he rllsult of work by ,8 tea m of ,eng<strong>in</strong>ears and<br />
was cold to ., Cb<strong>in</strong>ese chemical plant<br />
compression canal! be handled by one<br />
gearbox. <strong>in</strong> lead of requir<strong>in</strong>gevera]<br />
separate stand-alone units, Potter says.<br />
The space-efficiency of <strong>the</strong> <strong>in</strong>tegral<br />
gear unit is accompanied by operat<strong>in</strong>g<br />
efficiency=-thrust collars elim<strong>in</strong>ate <strong>the</strong><br />
need for higb speed thrust bear<strong>in</strong>gs, and<br />
power losses are typically lower than<br />
stand-alone unit. Also, iace<strong>the</strong> journal<br />
bear<strong>in</strong>gs for <strong>the</strong> compressor wheel are<br />
dim,<strong>in</strong>ated (<strong>the</strong> i.mpellers are mounted on<br />
<strong>the</strong> pi nions and <strong>the</strong> compressor uses gear<br />
unit bear<strong>in</strong>gs). a fur<strong>the</strong>r redaction <strong>in</strong> system<br />
power los is realized.<br />
The freedom <strong>in</strong> elect<strong>in</strong>g different<br />
p<strong>in</strong>ion peeds allow an optimization of !<br />
<strong>the</strong> aerodynamic effi.ciency<strong>in</strong> each tage :<br />
of compression, Potter ays. This<br />
expla<strong>in</strong>s why <strong>the</strong> overall power loss of<br />
an <strong>in</strong>regralgeared compres 'or i typically<br />
much lower than rand-alone unit .<br />
With <strong>the</strong> ability to drive up to to<br />
flange-mounted impellers, <strong>the</strong> units are<br />
equipped with thrust collars to elim<strong>in</strong>ate<br />
<strong>the</strong> high speedthrust bear<strong>in</strong>gs. The collars<br />
transfer <strong>the</strong> th rust to <strong>the</strong> bull gear.<br />
where <strong>the</strong> axial load is taken bya [ow<br />
peed thrust bear<strong>in</strong>g. The compressors'<br />
impellers are eared all extended. p<strong>in</strong>ion<br />
shaft. and <strong>the</strong> pirafhous<strong>in</strong>g are flange<br />
mounted<br />
onto <strong>the</strong> gear hous<strong>in</strong>g.<br />
Featur<strong>in</strong>g <strong>in</strong>gle-helical gear<strong>in</strong>g with<br />
p<strong>in</strong>ion of thrust collar de ign, <strong>the</strong> gearbox<br />
design holds upper and lower hou -<br />
109 components for two- to four-stage<br />
applications. For five- to eight- tage<br />
designs ..customers<br />
can use upper, middle<br />
and lower hou mg component .<br />
To have n<strong>in</strong>e- and IO-stage compresor<br />
applications, <strong>the</strong> customer has to<br />
<strong>in</strong>stall a fifth p<strong>in</strong>ion below <strong>the</strong> bun gear.<br />
This pillion also call drive <strong>the</strong> bull gear<br />
and gearbox for turb<strong>in</strong>e applications.<br />
Regardless of <strong>the</strong> end use. Europeans<br />
are buy,<strong>in</strong>g tile <strong>in</strong>tegral gear unit elll<br />
masse. S<strong>in</strong>ce February, 50 units have<br />
been sold by BHS·C<strong>in</strong>c<strong>in</strong>nati, which is<br />
manufactur<strong>in</strong>g <strong>the</strong>m at a rate of about<br />
100 units a year. A full 90 percent of<br />
<strong>the</strong>se mach<strong>in</strong>es are sold <strong>in</strong> Europe for<br />
U)O,OOO 'to 1 million euros, or about<br />
$92,000 to $9[8,000 apiece. The rest of<br />
<strong>the</strong> sales are split between companies <strong>in</strong><br />
America and Japan.O<br />
Ten Us Whit You Th<strong>in</strong>k. , .<br />
V"IIH www.,..,.lHroIogy.comto<br />
• RIle dIiI col ...<br />
• __ .... 11hnIIion<br />
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Come! See <strong>the</strong>' IN'ew Reishauer<br />
You know Reishauer<br />
lor superior Cont<strong>in</strong>uous<br />
Generat<strong>in</strong>g <strong>Gear</strong> Gr<strong>in</strong>d<strong>in</strong>g<br />
mach<strong>in</strong>es. This year at<br />
IMTS, along with a complete l<strong>in</strong>e of Diamondl<br />
IDr,Bss<strong>in</strong>g TOlIls" we'll <strong>in</strong>troduce Ihe completely<br />
new RZ 400. Incorporat<strong>in</strong>g all of <strong>the</strong> successful<br />
technology of our past series and much more,<br />
<strong>the</strong> new RZ 400 will revolutionize <strong>the</strong> way<br />
spur and helical gears are ground.<br />
RZ4'DOIn Acli:on •.,.,<br />
The RZ 400 r,educes manufactur<strong>in</strong>g costs tIlrough:<br />
• Increased flexibility for a variety 01 tooth geometries<br />
• Substantially faster cycle times<br />
• Rapid changeovers lor small lot size production<br />
• Automatic load<strong>in</strong>g as a standard option<br />
Make a pit stop <strong>in</strong> <strong>the</strong> Reishauer booth to have one of<br />
our Pertormance Team take for you lor a sp<strong>in</strong> around<br />
<strong>the</strong> future of hard gears.<br />
flEISHAUEFI<br />
Reishauer Corporation Elg<strong>in</strong>, Il60123<br />
ph: 847-888-3828<br />
VNffl. reishauer.com<br />
fax: 847-888.Q343<br />
IIIIIIIIIIII,pollll8r'rsnsmission.com· IIII"'IIII,(J811rI9Chnoio!1y.com • GEAR TECHNOLOGY' .J'ULYIAUGUST <strong>2002</strong> 11
... _ •• -.- -IIIMTS<strong>2002</strong>1 ----------.<br />
20'O-2-,FAQ!-- I _ IS a,n ~-Id-! Pasilion _ __ _ Info.' _<br />
Rob<strong>in</strong> W,right<br />
IMTS PAVIUO IS<br />
Abrasive Mac'hi,n<strong>in</strong>gJSaw<strong>in</strong>gJIFl<strong>in</strong>is'll<strong>in</strong>g-!North Build<strong>in</strong>g. HaIlIB,<br />
This pavilion will feature cyl<strong>in</strong>drical gr<strong>in</strong>ders; <strong>in</strong>ternal gr<strong>in</strong>ders;<br />
angular wheelside gr<strong>in</strong>ders; creep feed gr<strong>in</strong>ders; thrufeed<br />
gr<strong>in</strong>ders; centerless gr<strong>in</strong>ders; surface gr<strong>in</strong>ders; abrasive belt<br />
gr<strong>in</strong>ders: jig gr<strong>in</strong>ders; CNC tool and cutter gr<strong>in</strong>ders; universal<br />
gr<strong>in</strong>ders; earngr<strong>in</strong>ders: bench, crankshaft and abrasive cutoff<br />
mach<strong>in</strong>es; band saws; circular saws; lapp<strong>in</strong>g mach<strong>in</strong>es; balanc<strong>in</strong>g<br />
mach<strong>in</strong>es; hon<strong>in</strong>g mach<strong>in</strong>es and polish<strong>in</strong>g mach<strong>in</strong>es,<br />
IControlsand CAD-CAMI-EastIBuild<strong>in</strong>g, Halll D<br />
This pavilion focuses on CIMICAD/CAM<br />
systems, CNC controls,<br />
automation management systems, communications systerns<br />
and LANs, software development systems and services,<br />
computers and software, <strong>in</strong>struments-controls and systems <strong>in</strong>tegration<br />
services.<br />
IEDMI-East Build<strong>in</strong>g l , HalilD<br />
One of <strong>the</strong> Jargest ga<strong>the</strong>r<strong>in</strong>gs of EDM manufacturers ever<br />
assembled, <strong>the</strong> pavilion features C C wire EDM, EDM filtration<br />
system and supplies, ram-type EDM, metal dis<strong>in</strong>tegrators<br />
and die s<strong>in</strong>k<strong>in</strong>g mach<strong>in</strong>es.<br />
12 JULY/AUGUST <strong>2002</strong>' GEAR TECHNOLOGY' www.g6llrtechnology.com' www.powerlransmlsslon,com
_____ IIMT.S.<strong>2002</strong> _<br />
<strong>Gear</strong> Gen.eration-N'orth Buiild<strong>in</strong>gl. Hall B:<br />
<strong>Gear</strong> bobbers, gear shapers, gear cutter, gear shavers, broach<strong>in</strong>g<br />
equipment, gear gr<strong>in</strong>d<strong>in</strong>g equipment and gear measur<strong>in</strong>g<br />
equipment are howcased <strong>in</strong> this pavilion.<br />
Mach<strong>in</strong>e' Com,ponents/CleanilngjEnvironmenCa,I-East Build<strong>in</strong>g.<br />
Hall D<br />
Air purification equipmeot and services, sat:ety guards, mats and<br />
equipment, filtralion equipment, water and oil purification, air filtration,<br />
oil separation, ump cleaners, noise control equipment,<br />
dust removers, electrical equipment, way covers/tracks, storage<br />
systems,<br />
parts cleaners, parts washers, materials handl<strong>in</strong>g/storage<br />
ystem ,'ball crews, bear<strong>in</strong>gs, sp<strong>in</strong>dle, conveyors. coat<strong>in</strong>gs,<br />
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IWww.p,,·werlran$ffli$sicm.com " WWW.ge8fI8cllnology.com • ClEAR TECHNOLOGY' JULY/AUGUST <strong>2002</strong> 15
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<strong>2002</strong> S!HOW INDilCATES MI,NIMAL<br />
RECESSION DAMA'GE<br />
Despite <strong>the</strong> <strong>in</strong>dustry's economic hardship, projections for <strong>the</strong><br />
IMTS <strong>2002</strong> Show <strong>in</strong>dicate a relatively normal level of activity.<br />
Early figures from AMT reflect that attendance at this year's<br />
75th anniversary<br />
show will be similar <strong>in</strong> number to <strong>the</strong> last<br />
show, held <strong>in</strong> 2000. Approximately 100,000 professionals have<br />
completed <strong>the</strong> preregistration procedure, which is close to <strong>the</strong><br />
110,000 attendees who turned out two years ago. Figures for <strong>the</strong><br />
number of <strong>in</strong>ternational registrants are about equal' to that of<br />
those com<strong>in</strong>g from overseas <strong>in</strong> 2000.<br />
Organizers estimate that $804 million <strong>in</strong> sales will be transacted<br />
at this September's show, which would top <strong>the</strong> $800 million<br />
reached <strong>in</strong> 2000.<br />
As far as floor space <strong>in</strong> <strong>the</strong> exhibit hall, <strong>the</strong>re is a 4 percent<br />
reduction <strong>in</strong> <strong>the</strong> number of exhibits scheduled for September's<br />
show. However, more cancellations and additions of booths-as<br />
well as changes <strong>in</strong> <strong>the</strong> size of floor space per company-have<br />
taken place for this year's show, says John Krisko. exhibition<br />
market<strong>in</strong>g director.<br />
"We've already made over 500 changes," Krisko says.<br />
"Where we've downsized someone, we've upsized someone<br />
else."<br />
Additionally, Krisko anticipates a strong show<strong>in</strong>g due to predictions<br />
about an upturn <strong>in</strong> <strong>the</strong> American economy.<br />
"We're fortunate that <strong>the</strong> tim<strong>in</strong>g is such that <strong>the</strong> show will<br />
take place at a time when <strong>the</strong> bus<strong>in</strong>ess cycle is pick<strong>in</strong>g up," he<br />
says. "The IMTS.is <strong>the</strong> <strong>in</strong>dusry's major mach<strong>in</strong>e tools show and<br />
will be at <strong>the</strong> lead<strong>in</strong>g edge of <strong>the</strong> economic recovery."<br />
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~ AGl\1A's Fall TcchnicalMcct<strong>in</strong>g A<br />
October 20-22. <strong>2002</strong> • St. Louis, Missouri WI<br />
16, JULY/AUGUST <strong>2002</strong> • GEAR TECHNOLOGY. www.geartechno1ogy.com· www.oowenrensmts ston.com
_ •••••<br />
-IIIMTS<strong>2002</strong>.-----1<br />
FOR EXHIBITS OF THE LATEST<br />
GEAR PRODUCTS, VISIT THESE<br />
COMPANIES ••.<br />
A/W..,.. Co.""<br />
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RIir....., AcCl ••• " Co., II1II n.<br />
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with gear IDspection devices. Put your trust <strong>in</strong> <strong>the</strong><br />
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IMTS, OFFERS 'T'ECHNIIC:AILCO:NFERENCE<br />
In addition 10 walk<strong>in</strong>g <strong>the</strong> exhibit floor, IMTS attendees have<br />
<strong>the</strong> option of til<strong>in</strong>g part <strong>in</strong> <strong>the</strong> 60+ conference sessions that<br />
focu on various manufactur<strong>in</strong>g practices.<br />
The categorie offered for <strong>the</strong> !MTS <strong>2002</strong> Manufactur<strong>in</strong>g<br />
Conference are:<br />
Mach<strong>in</strong><strong>in</strong>g-<strong>in</strong>cludes emerg<strong>in</strong>glrends andhigh-peed mach<strong>in</strong><strong>in</strong>g,<br />
Gr<strong>in</strong>d<strong>in</strong>g & Abrasives~a focus. on <strong>the</strong> latest technoiogies,<br />
Tool<strong>in</strong>gs-se sions on design eng<strong>in</strong>eer<strong>in</strong>g and rapid root<strong>in</strong>g,<br />
Qualily-slIategiesandsix sigma applications <strong>in</strong> manufacturi IIg,<br />
Job Sbops---concentrat<strong>in</strong>g on <strong>the</strong> unique need of contract and<br />
small manufactur<strong>in</strong>g operators. and<br />
~'lanufadur<strong>in</strong>g Strategtes=prevides sessions on lean manufactur<strong>in</strong>g<br />
practices, advances <strong>in</strong> manufactur<strong>in</strong>g automation as<br />
well as supply cha<strong>in</strong> and resource management and reels,<br />
All of <strong>the</strong> sessions focus on issues Like<strong>in</strong>creas<strong>in</strong>g productivity,.<br />
strategies for reduc<strong>in</strong>g lead time, tools for assur<strong>in</strong>g quality<br />
and <strong>the</strong> latest technical developments. SME organizers have<br />
cheduled speakers who <strong>in</strong>clude executives at companies such<br />
as Motorola Inc.. Visteon Corp. and Lean Works Inc.<br />
In addition to <strong>the</strong> peeches, attendees have <strong>the</strong> opportunity to<br />
network with o<strong>the</strong>r <strong>in</strong>du try professionals dur<strong>in</strong>g <strong>the</strong> technical<br />
conference. The <strong>in</strong>tended audience consists of people with management.<br />
eng<strong>in</strong>eer<strong>in</strong>g. design, upervision, quality control.<br />
human resource , sales and market<strong>in</strong>g, pu,rcnas<strong>in</strong>g.<br />
operations and ma<strong>in</strong>tenance functions.<br />
production<br />
For jhose hold<strong>in</strong>g member hips <strong>in</strong> SME, <strong>the</strong> conference is<br />
free on September 9. For o<strong>the</strong>r cost <strong>in</strong><strong>format</strong>ion, visit<strong>the</strong> SME<br />
web ite at www.sme.orglimts.<br />
For more <strong>in</strong><strong>format</strong>ion onme conference schedules for <strong>the</strong> six.<br />
categorie • vi it<strong>the</strong> mMTShomepage at u'ww.imts.org me-mail<br />
<strong>the</strong> IMTS <strong>2002</strong> ManllfaclUr<strong>in</strong>g Conference team at<br />
mfgconf@sme.org.<br />
STUDENT SUMM'!IT I,NTRODUCES INEXT<br />
GENIEIRATIIONITO IMANUFA'CTURI,NG<br />
The IMTS <strong>2002</strong> Show offers an opportunity for tudents, rang<strong>in</strong>g<br />
from grade school ro college. to take part <strong>in</strong> <strong>the</strong> exhibition.<br />
This opportunity started al <strong>the</strong> I998 show and attendance<br />
rose II % by <strong>the</strong> time of IMTS 2000. accord<strong>in</strong>g to <strong>the</strong> IMTS<br />
website.<br />
Whe<strong>the</strong>r <strong>the</strong>se<br />
ruderns are college seniors ready to enter <strong>the</strong><br />
eng<strong>in</strong>eer<strong>in</strong>g field or <strong>in</strong> elementary school. <strong>the</strong>y will have <strong>the</strong><br />
opportunity (0 visit<strong>the</strong> <strong>in</strong>side of <strong>the</strong> booths and speak 10 company<br />
representatives to better understand <strong>the</strong> technology. In <strong>the</strong><br />
past. older students took advantage of this opportunity <strong>in</strong><br />
greater number<br />
but an ages are <strong>in</strong>vited. accord<strong>in</strong>g to posted statisues<br />
on <strong>the</strong> IMTS website.<br />
A goal of<strong>the</strong> student ummit is to <strong>in</strong>troduce <strong>the</strong> tudents to<br />
career opportunities ande pla<strong>in</strong> <strong>the</strong> future of <strong>the</strong> manufactur<strong>in</strong>g<br />
technology <strong>in</strong>dustry,<br />
Teachers and parents are also permitted toparticipate <strong>in</strong> <strong>the</strong><br />
student. summit. Show it<strong>in</strong>eraries and assignments are available<br />
to teachers.<br />
In 2IXX), atotal of 3,923, students were chaperoned through<br />
<strong>the</strong> IMTS show by 605 teachers and parents. The students and<br />
<strong>the</strong>ir chaperones represented 35 states and 13 foreign countries,<br />
Registration is free for <strong>the</strong> student summit and students may<br />
attend on any day of [MTS.<br />
Interested rudents and <strong>in</strong>dustries can obta.<strong>in</strong> forms on <strong>the</strong><br />
IMTS web page. For more <strong>in</strong><strong>format</strong>ion, call Myrta Mason at<br />
(703) 827-5219 or e-mail her at mamason@c1nltonl<strong>in</strong>e.org.<br />
Tell Us What YouTh<strong>in</strong>k ...<br />
Visit our website al www.g'lIrtechno/ogy.com to<br />
• Rate this article<br />
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,·8 JULY/AUGUST <strong>2002</strong> .,. GEAR TECHNOLOGY' wlllw.gtlllfl.chnoIOfJy.com ,. www.pOWBrlrBf!Bmission ..com
Chan.<br />
fer tl Inc.<br />
a tc<br />
CHAMFERMAnc,<br />
INC.<br />
7842 Burden Road<br />
Machesney Park, IL 61115<br />
Tel: 815-636-5082<br />
Fax: 815-636-0075<br />
E-mail: chamfer96@aoLcom
<strong>Gear</strong> Surface Durability<br />
Development to Enhance<br />
--ower - .Ienslty<br />
T ransmlSSl,on .. PD·<br />
J'oe, Chen. ,John Flynn ,and Ge·off Semr,BUI<br />
Intreductkm<br />
<strong>Gear</strong> pitt<strong>in</strong>g is one of <strong>the</strong> primary failure<br />
modes of automotive transmission gear sets. Over<br />
<strong>the</strong> past years, many alternatives have been<br />
<strong>in</strong>tended to improve <strong>the</strong>ir gear surface durability.<br />
However, due to <strong>the</strong> nature of new process development,<br />
it takes a length of time and jciot efforts<br />
between <strong>the</strong> development team and suppliers to<br />
<strong>in</strong>vestigate and verify each new approach,<br />
FiglJre 1 Back-lo-back planetary gear .component test ItWcMne and flXl!lr~.<br />
Table 1- Test MaIm lor Surface lJurabilily Comparison<br />
1. B asel.<strong>in</strong>e vs. IRedesign<br />
2. Materiall Selectio~Slln l[jear 11011'1'. Use Standard, Planets II R<strong>in</strong>g <strong>Gear</strong> (orJest<strong>in</strong>gl<br />
Sun '<strong>Gear</strong> Materials<br />
AISI!SA:E[U.SAI Steels European Steels<br />
4620M !Ba ssl<strong>in</strong> II I 8620 I 9310 I '5120 18COII I 25C04 I 3OC04<br />
X X. X. X X<br />
I<br />
X<br />
I X<br />
3. Ml!nufactllr<strong>in</strong>g P~Dcess,........lJslllStandard IR<strong>in</strong>g ,<strong>Gear</strong> for Test<strong>in</strong>g<br />
Sun GlIBr Process<br />
Planets Basel<strong>in</strong>e Honed Coat<strong>in</strong>g n ual Shot Peen<strong>in</strong>g Isotropic 1 Isotropic 2<br />
Prod. planet X X X X<br />
Without Shot<br />
Deburr<strong>in</strong>g<br />
X<br />
Honed X X<br />
Planets<br />
Iisotropic 1 X<br />
lsotropic 2 X<br />
,<br />
New and upgraded transmissions have required<br />
a. higher <strong>in</strong>put power capability<br />
to meet <strong>the</strong><br />
customers' expectations, Increas<strong>in</strong>g <strong>the</strong> power<br />
density In <strong>the</strong> transmission gear system was<br />
urgently demanded, To. shorten <strong>the</strong> development<br />
lime <strong>in</strong> thi area, GM Powertra<strong>in</strong>'s Advanced<br />
<strong>Gear</strong> Sy tems 'Group <strong>in</strong>itialed a systematic<br />
approach to evaluate altemarives that had <strong>the</strong><br />
potential to meet <strong>the</strong> needs. In addition to a s<strong>in</strong>gletooth<br />
bend<strong>in</strong>g project for a gear bend<strong>in</strong>g fatigue<br />
study and jo<strong>in</strong>t projects with bear<strong>in</strong>g suppliers to<br />
improve <strong>the</strong> durability of planetary bear<strong>in</strong>gs (Ref.<br />
I), a comprehensive gear surface durability<br />
improvement project was established.<br />
This study is at prelim<strong>in</strong>ary assessment of <strong>the</strong><br />
effects of apply<strong>in</strong>g different design methodologies,<br />
material selections and manufactur<strong>in</strong>g<br />
proce ses on gear surface durability. Ba ed on this<br />
analy is, an <strong>in</strong>-depth study willfellow to fur<strong>the</strong>r<br />
understand <strong>the</strong> benefits of us<strong>in</strong>g differem alternatives<br />
for future applications.<br />
Objective of tbe Stud.y<br />
• To evaluate and verify <strong>the</strong> effects of design,<br />
material selection and manufactur<strong>in</strong>g process on<br />
power density of planetary transmis ion gear ets,<br />
• To exam<strong>in</strong>e and <strong>in</strong>terpret <strong>the</strong> effects of factors,<br />
uch as surface roughness, residual tres .coat<strong>in</strong>g,<br />
material properties and geometry variations on<br />
gear urface durability.<br />
• To understand benefit and risk factors of each<br />
variant for future application .<br />
.Metbodology<br />
All re Is were conducted at<strong>the</strong> GM Pewenra<strong>in</strong><br />
<strong>Gear</strong> Laboratory us<strong>in</strong>g aback-to-back planetary<br />
gear component test mach<strong>in</strong>e with a specially<br />
designed<br />
20 JULY/AUGUST <strong>2002</strong> • GEAR TECHNOLOGY" ......w.gnrltlchl1olog)l.com • w'w....po ..... rlrl'l1lmission.com<br />
test fixture (Fig, O. An exist<strong>in</strong>g planetary<br />
gear set was chosen as <strong>the</strong> basel<strong>in</strong>e because its<br />
surface durability characteristics were well<br />
known, and its design permitted easy <strong>in</strong> pectien<br />
I and ma<strong>in</strong>tenance,
The test matrix for <strong>the</strong> surface durability study<br />
is shown <strong>in</strong> Table 1. II consists of two different<br />
design approaches. seven material selections, and<br />
n<strong>in</strong>e manufactur<strong>in</strong>g processes.<br />
Design specifications and stress calculations<br />
are shown <strong>in</strong> Table 2. The stresses are based on a<br />
torque of 1,500 N-m at <strong>the</strong> r<strong>in</strong>g gear. Lead taper<br />
is not considered <strong>in</strong> <strong>the</strong> stress calculations.<br />
The test samples were thoroughly <strong>in</strong>spected<br />
before <strong>the</strong> test Relevant features of each test pari<br />
were identified and recorded for future reference.<br />
The gears were orig<strong>in</strong>ally tested at. a constant<br />
torque of ].500 N-m at <strong>the</strong> reaction arm and a<br />
constant speed of 1,500 rpm at <strong>the</strong> <strong>in</strong>put sp<strong>in</strong>dle.<br />
Under <strong>the</strong>se conditions, however, <strong>the</strong> redesigned<br />
gear set did not pit ill a reasonable period of time<br />
and displayed <strong>in</strong>consistent failure modes.<br />
Increas<strong>in</strong>g <strong>the</strong> torque to 2,'000 N-m produced <strong>the</strong><br />
desired results.<br />
The test matrix was run <strong>in</strong> a random pattern to<br />
satisfy <strong>the</strong> statistical requirement for a small sample<br />
size.. The random pattern is also helpful <strong>in</strong><br />
detect<strong>in</strong>g faults <strong>in</strong> <strong>the</strong> mach<strong>in</strong>e and fixture sett<strong>in</strong>gs<br />
dur<strong>in</strong>g test<strong>in</strong>g.<br />
Failure was achieved when any tooth flank<br />
developed a pit with all area of ].0 mm 2 at a depth<br />
exceed<strong>in</strong>g<br />
L5 mm. Pit size was measured by a<br />
computerized optical image device.and pit depth<br />
was assessed with a gear profile <strong>in</strong>spection<br />
mach<strong>in</strong>e.<br />
A Weibun analysis (Ref. 2) was performed to<br />
establish life ranks,<br />
A metallurgical failure analysis was performed<br />
on selected samples for a better understand<strong>in</strong>g of<br />
<strong>the</strong> causes of <strong>the</strong> failure.<br />
Test Results<br />
Design Appmach. The basel<strong>in</strong>e planetary gear<br />
set was designed approximately 20 years ago and<br />
has been used <strong>in</strong> various transmissions s<strong>in</strong>ce <strong>the</strong>n.<br />
Recently, <strong>in</strong>creased eng<strong>in</strong>e power and more str<strong>in</strong>gent<br />
noise specifications caused this design to<br />
become obsolete. A new gear set. with enhanced<br />
capabilities but fitt<strong>in</strong>g <strong>in</strong> <strong>the</strong> same space, was <strong>the</strong>n<br />
produced, The design approaches of <strong>the</strong>se two<br />
gear systems are quite different. The orig<strong>in</strong>al<br />
design used a relatively coarse pitch to enhance<br />
<strong>the</strong> tooth bend<strong>in</strong>g strength and adopted lead taper<br />
to reduce <strong>the</strong> gear force fluctuation.<br />
The use of taper moderates vibration levels by<br />
prevent<strong>in</strong>g <strong>the</strong> sudden release of load at <strong>the</strong> tooth<br />
trail<strong>in</strong>g end (Ref. 3). The redesign uses a f<strong>in</strong>er<br />
pitch to <strong>in</strong>crease both <strong>in</strong>volute and helical. contact<br />
ratios and <strong>in</strong>corporates profile modifications to<br />
'Optimize <strong>the</strong> load distribution. Based on 3-B FEA<br />
Design<br />
Base Design<br />
IRedesign<br />
Normal Module 1.630 1.439<br />
<strong>Gear</strong> Ratio 3.33, 3.29<br />
Normal Pressure Angle 20.00 19'.00<br />
Helix Angle 18.00 2MO<br />
Total Conta ct Ratio 2.69 3.63<br />
Lead Modification 0-36 um O+/-tBj.lm<br />
Stress 'CDmparison<br />
Base Design<br />
Redesigll'<br />
Bend<strong>in</strong>g (MPa! 512 513<br />
Compressive IMPa.! 1,510 1,250<br />
'60 BASELINE FINAL DAIVE<br />
OUT.PUT SPEeo • APPROX. 600-700 RPM<br />
1ST ORDER. FINAL DRIVE<br />
CARRIER<br />
ROT.<br />
20 ,.;.......J'<br />
,ai'Basel<strong>in</strong>e'<br />
Design<br />
Table 2-Design<br />
60 4T40-E FIN>\L ORIVE GEAR GeOM!OrRY<br />
OUTPUT SPEED. APPROX. 600-700 RPM<br />
1ST ORDER. FINAL OArVE<br />
CARRIER ROT.<br />
40<br />
20~ ~<br />
Figure 2-Cear<br />
b) Redesign<br />
Comparison<br />
noise alia vibration levelcomparisOlI.<br />
model<strong>in</strong>g, <strong>the</strong> new design has better load distributionand<br />
lower overall. tooth compressive stress<br />
than <strong>the</strong> basel<strong>in</strong>e gear set. Noise and vibration<br />
tests verified that <strong>the</strong> new design has a substantially<br />
lower gear mesh noise level (Fig. 2).,<br />
Jee Chen<br />
is a staff project<br />
------<br />
eng<strong>in</strong>eer<br />
witt: GM Powertra<strong>in</strong> <strong>Gear</strong><br />
Center ill Wixom. MI.<br />
He holds a master of sciem:e<br />
degree ill mechanical<br />
eng<strong>in</strong>eer<strong>in</strong>g, as well as a<br />
master's degree <strong>in</strong> bus<strong>in</strong>ess<br />
adm<strong>in</strong>istration. He has<br />
more than 25 years of<br />
experience <strong>in</strong> gear system<br />
design and devetopmeni for<br />
all· and off-highway<br />
transmissions.<br />
John Flynn<br />
is a senior project<br />
eng<strong>in</strong>eer<br />
with <strong>the</strong> GM Powertra<strong>in</strong><br />
<strong>Gear</strong> Center and <strong>the</strong> OM<br />
Powertra<strong>in</strong> Applicarioll<br />
Group. HI! holds a bachelor's<br />
degree In memllurgical<br />
eng<strong>in</strong>eer<strong>in</strong>g arId a master<br />
s degree III bus<strong>in</strong>ess<br />
adm<strong>in</strong>istration. He lias<br />
more than 11 years of<br />
experience 111 metallurgical<br />
and failure analysis.<br />
Geoff Semrau<br />
is a senior projecteng<strong>in</strong>eer<br />
witn <strong>the</strong> GM Powertm<strong>in</strong><br />
Base Transmission Group.<br />
He holds a master oj sci-<br />
As was mentioned above, <strong>the</strong> two designs (mce degree i", mechanical<br />
were tested under different load<strong>in</strong>g conditions. eng<strong>in</strong>eer<strong>in</strong>g ..He has been<br />
witl: OM Powertra<strong>in</strong> for 18<br />
Figure. 3 shows <strong>the</strong> pitt<strong>in</strong>g life comparison<br />
years, and he specializes <strong>in</strong><br />
between <strong>the</strong> basel<strong>in</strong>e and redesigned gear sets. gear system development<br />
Figure 4 shows <strong>the</strong> correspond<strong>in</strong>g WeibuU analy- and analysis.<br />
WWW.pow8rtransm eston.com » Www.gB8rtBchn0/ogy.com' GEA.R TECHNOLOGY, JULy/AUGUST <strong>2002</strong> 21
99.00<br />
90.00<br />
50.00<br />
if<br />
~ '" ~<br />
t: 10.00<br />
:::J<br />
5.00<br />
1.00<br />
Figure 4-Weibull<br />
70<br />
;~ 60<br />
iii<br />
if<br />
~ 50<br />
:E<br />
C!<br />
40<br />
A<br />
~<br />
:::l<br />
0<br />
;;.<br />
30<br />
of<br />
:::i 20<br />
CI<br />
.:'<br />
E<br />
ii 10<br />
0<br />
;HiD<br />
18D<br />
16:Ct<br />
,..,<br />
"E E<br />
0<br />
.."<br />
'i<br />
f<br />
'""<br />
;.<br />
~<br />
g' 00<br />
jj<br />
..<br />
••<br />
..<br />
••<br />
IRedJ!ollgl!(CAiatJoIIlidi<br />
",""""<br />
Figure 3-Sun gear pitt<strong>in</strong>g life comparison<br />
between designs.<br />
10.00 100.00 1.000.00<br />
Pitt<strong>in</strong>g Failure Hours (> 1.0 mm»<br />
• 3.33 Ratio (wi 1.500 N·m) ... 3.29 Ratio (wl.2,000 N·m) !! 3.29 Ratio (wi 1,500 N-m)<br />
~1=3.a2. ~1=44.15. p=0.98 ~2=6.72. ~2 =48.28 ~3=6.72, n8=127.48<br />
4620M 8620<br />
Basel<strong>in</strong>e<br />
Figure S-SZllt gear piu<strong>in</strong>g<br />
allalysis for design comparison.<br />
9310 51'20 18CD4 25C04 30CD4<br />
Mal.eriall.D.<br />
life camp.arisonamong materials.<br />
22 JULY/AUGUST 200.2 ,. GEAR TECHNOLOGY' www.geartechnology.com' www.powertrenemisstori.com<br />
sis result of <strong>the</strong>se two design approaches,<br />
The<br />
analysis shows that <strong>the</strong> basel<strong>in</strong>e coarser pitch sun<br />
gear has a B-50 pitt<strong>in</strong>g life of 40 hours. This compares<br />
to 46 hours at <strong>the</strong> higher load or 120 hours<br />
at <strong>the</strong> same load for <strong>the</strong> f<strong>in</strong>er pitch gear set. The<br />
120 hours is determ<strong>in</strong>ed by extrapolation us<strong>in</strong>g an<br />
SIN curve with slope of 3.375. The data <strong>in</strong>dicate<br />
that a significant improvement <strong>in</strong> pitt<strong>in</strong>g life has<br />
been achieved by <strong>the</strong> redesign.<br />
Material Selection. Seven common gear steels<br />
were selected for surface durability test<strong>in</strong>g,<br />
Figure 5 shows <strong>the</strong> surface durability test results,<br />
and Figure 6 shows <strong>the</strong> Weibull analysis. The<br />
sample gears were identical <strong>in</strong> design and manufacture,<br />
Several parameters possibly affect<strong>in</strong>g<br />
surface durability were tabulated, Table 3 shows<br />
<strong>the</strong> chemical composition. reta<strong>in</strong>ed austenite,<br />
case depth and hardness of each material. Table 4<br />
shows a comparison of surface f<strong>in</strong>ishes.<br />
Manufactur<strong>in</strong>g Processes. Seven different<br />
manufactur<strong>in</strong>g processes were evaluated. Both<br />
sun and p<strong>in</strong>ion gears were fabricated us<strong>in</strong>g <strong>the</strong><br />
various processes, and a total of n<strong>in</strong>e comb<strong>in</strong>ations<br />
were tested (Table I). Standard r<strong>in</strong>g gears<br />
were used for all tests. To elim<strong>in</strong>ate unwanted<br />
variations, <strong>the</strong> test gears-except those to be<br />
honed-were manufactured and heat treated as a<br />
s<strong>in</strong>gle lot and later f<strong>in</strong>ished by <strong>the</strong> specific<br />
method. Figure 7 shows <strong>the</strong> durability life comparison<br />
of <strong>the</strong> manufactur<strong>in</strong>g processes, and<br />
Figure 8 shows <strong>the</strong> Weibull analysis that ranks all<br />
<strong>the</strong> test variants,<br />
The test results reveal that manufactur<strong>in</strong>g<br />
processes can have a significant effect on <strong>the</strong> surface<br />
durability, While fur<strong>the</strong>r <strong>in</strong>vestigation is<br />
needed, some general observations may be made:<br />
The surface f<strong>in</strong>ish of <strong>the</strong> planet p<strong>in</strong>ions has a<br />
great <strong>in</strong>fluence on <strong>the</strong> sun gear durability. This is<br />
illustrated as follows:<br />
.' Honed sun gears run with standard p<strong>in</strong>ions have<br />
only one-third <strong>the</strong> life of standard sun gears run<br />
with honed p<strong>in</strong>ions .. The honed p<strong>in</strong>ions have a<br />
better surface f<strong>in</strong>ish than <strong>the</strong> standard p<strong>in</strong>ions.<br />
• Honed sun gears run with standard p<strong>in</strong>ions have<br />
approximately one-fourth <strong>the</strong> life of honed sun<br />
gears run with honed p<strong>in</strong>ions.<br />
• The shot deburr<strong>in</strong>g process, which is <strong>in</strong>tended<br />
to remove gear edge burrs and heat-treatment<br />
scale, is detrimental to gear life if poorly controlled,<br />
Standard sun gears run with p<strong>in</strong>ions<br />
that were not subjected to shot deburr<strong>in</strong>g have<br />
four times <strong>the</strong> life of <strong>the</strong> standard SUll gears run<br />
with p<strong>in</strong>ions that were shot deburred. The shot<br />
deburr<strong>in</strong>g process produces much rougher sur-
faces on <strong>the</strong> gear teeth arid. if not under tight<br />
control. can cause severe surface damage.<br />
Figure 10 shows a comparison of gear teeth<br />
before and after a poorly controlled shot deburr<strong>in</strong>g<br />
operation.<br />
Both isotropic urface f<strong>in</strong>ish<strong>in</strong>g processes<br />
(Rd. 4) use a sequence of chemkaland<br />
mechanical, operations to smooth <strong>the</strong> gear surface<br />
by remov<strong>in</strong>g a few micrometers of material.<br />
One of <strong>the</strong>se proprietary proces es appears<br />
to have <strong>the</strong> potential of enhanc<strong>in</strong>g surface durability<br />
when both mat<strong>in</strong>g gears ace treated.<br />
Compressive reoidual stres near <strong>the</strong> tooth<br />
fillet has long been recognized as contribut<strong>in</strong>g<br />
to <strong>in</strong>c rea ed gear tooth bend<strong>in</strong>g life. The same<br />
<strong>the</strong>ory can also be applied to gear surface durability<br />
(Ref. 5) with a certa<strong>in</strong> degree of uccess,<br />
WI is imperative, however, that <strong>the</strong> gear surface<br />
not ub tantially damaged by <strong>the</strong> process<br />
used '10 impart that compre sive residual stress.<br />
Figure 10 how <strong>the</strong> comparison of <strong>the</strong> residual<br />
stress produced by <strong>the</strong> conventional and two<br />
secondary proce se . The dual shot peen<strong>in</strong>g and<br />
<strong>the</strong> hon<strong>in</strong>g process. both completed after heat<br />
treatment, add compressive re idual stress to<br />
<strong>the</strong> gear surface. These stresses will reduce urface<br />
crack progre . ion and thu <strong>in</strong>crease useful<br />
gear life. The duaJhol peen<strong>in</strong>g requires two<br />
different hot size and <strong>in</strong>tensities, The coarser<br />
shot provides deep penetration at <strong>the</strong> root, and<br />
<strong>the</strong> f<strong>in</strong>er shot produces high compres ive re idual<br />
stress close to <strong>the</strong> surface. Similarly. <strong>the</strong><br />
hoa<strong>in</strong>g proce s provide high compressive<br />
residual stre dose to <strong>the</strong> tooth surface,<br />
All test ariant except <strong>the</strong> honed paris were<br />
conventionally bobbed and haved and <strong>the</strong>n<br />
batch heat-treated. However, tooth profile disiortion<br />
dur<strong>in</strong>g heal. treatment is not consistent<br />
from lot to lot or even part 1.0 part. Because <strong>the</strong><br />
hon<strong>in</strong>g process is completed after heat-treat<strong>in</strong>g,<br />
better profile consistency can be achieved.<br />
Table 5 shows a comparison of <strong>the</strong> profile<br />
control obta<strong>in</strong>ed by <strong>the</strong> conventional and hon<strong>in</strong>g<br />
processes. The much improved urface<br />
durability of <strong>the</strong> honed sun and planet re 111£<br />
from <strong>the</strong> comb<strong>in</strong>ation of benefits from con istent<br />
geometrical control and higher residual<br />
compressive stre s.<br />
<strong>Gear</strong> surface hardness i' essential. to susta<strong>in</strong><br />
extended gear life. on-metallic coat<strong>in</strong>gs can<br />
provide very high surface hardnes (HRc 90)<br />
and lower friction coefficients. The non-coated<br />
samples <strong>in</strong> this studyhad conventional surface<br />
and core hardness. The mechanism by which<br />
-<br />
l1li00<br />
QOOO<br />
'legend<br />
~ I 4620'M<br />
so 00 8620<br />
i<br />
.<br />
i' " 9310<br />
S 52.10<br />
! ~ o 18C04<br />
:J<br />
1000<br />
500<br />
100<br />
Figure ,6-Weibull' allalysi<br />
Ra(~ml<br />
flsk<br />
!'V1pm)<br />
Rms(~ml<br />
:'10:'<br />
!l.<br />
"e<br />
IE<br />
100 1000<br />
1'1'!LngUft (Hour.l ~l,Omrn·2I'JlSQ:.<br />
for mat'erial comparison.<br />
x 25C04<br />
+ 30CDA<br />
The ~mage surl·ece roughness<br />
Skewnm. a measure 01 symmetry of vellsys: e positive skew <strong>in</strong>dice!es e ·peaky' surlaci<br />
MWmwn peak'I~VIljey heigh! OYB/<strong>the</strong> sampl,<br />
The root·mean·square average 01 <strong>the</strong> measured height deviation taken l'Iith<strong>in</strong> <strong>the</strong> mlul~o" area end<br />
measured from <strong>the</strong> mean surtace<br />
140<br />
120<br />
100<br />
c:t .... 80<br />
"F<br />
::1'<br />
60<br />
!<br />
"<br />
:s<br />
'to<br />
40<br />
,e:<br />
=ii:<br />
20<br />
o<br />
..... ' --...:,' ... twit. ....... 1 ...... D.~ ..... MIM....,<br />
a... !!III!i!!iII. liIIII!!<br />
Figure 7-Momifaclurillg process ,effect OR'slm gear pitthlg life.<br />
www.pow9rtransmlsslon.com • Www.IlBSrr8chnolog'y.com· GEAR TECHNOLOGY' JULV/AUGUST <strong>2002</strong> ,23
coat<strong>in</strong>gs provide improved surface durability is<br />
not fully understood at this time and is <strong>the</strong> subject<br />
of cont<strong>in</strong>u<strong>in</strong>g research,<br />
figure II shows typical microstructure photographs<br />
of tested samples. Failure analysis<br />
conducted by <strong>the</strong> GM Pow-ertra<strong>in</strong> <strong>Gear</strong><br />
Laboratory revealed that most distress is surface-<strong>in</strong>itiated<br />
f<strong>in</strong>e gra<strong>in</strong> pitt<strong>in</strong>g. Surface cracks<br />
<strong>in</strong>itiat<strong>in</strong>g at <strong>in</strong>clusions were also found. The<br />
<strong>in</strong>clusions may have been non-metallic impurities<br />
<strong>in</strong> <strong>the</strong> steel or could have been caused by a<br />
manufactur<strong>in</strong>g operation. There were also flnd-<br />
.- _, 1!24.53, ,.1!1.5!1, ralS7<br />
ow.oPlnlon,~<br />
<strong>in</strong>gs of <strong>in</strong>tergranular oxidation ([GO), related<br />
,1l8o/L73,hio4Ul._<br />
+ II
gear with standard p<strong>in</strong>ions (4). isotropic 2 (5).<br />
standard sun gears mated with pillions that were<br />
not shot debarred (6), non-metalliccoated sun<br />
gear (7), standard sun gears with honed p<strong>in</strong>ions<br />
(8),. and sun gears and p<strong>in</strong>ions both hailed (9).<br />
Among tile characteristics produc<strong>in</strong>g significant.<br />
surface durability improvement are <strong>the</strong> surface<br />
f<strong>in</strong>ish, <strong>the</strong> residual stress pattern, <strong>the</strong> surface<br />
hardness. and superior tooth geometry control.<br />
Planet tooth surface roughne s appears to have<br />
a significant effect on <strong>the</strong> SUIl gear surface durabili.ty··O<br />
A,cknowledgments<br />
The accomplishment of this project occurred<br />
through tbe jo<strong>in</strong>t efforts of all <strong>the</strong> project team<br />
members, <strong>the</strong> manufactur<strong>in</strong>g facility of GMPT·St.<br />
Cathar<strong>in</strong>e and GM Powertra<strong>in</strong> gear lest and <strong>in</strong>spection<br />
laboratories. The authors would also like to<br />
express <strong>the</strong>ir appreciation to those who provided<br />
assi stance and <strong>in</strong><strong>format</strong>ion to this project.<br />
R,efer,ences.<br />
1. Chen. J. "Planetary eedle Bear<strong>in</strong>g<br />
Development to Enhance Transmission Power<br />
Density," To be published.<br />
2. PC· WAS WeibuU AJ1aiysis System User Guide,<br />
developed by EDS Group, March 1993.<br />
3. Hardy, A. "An Action Analysis of <strong>Gear</strong> Teeth<br />
With Modified Lead and Profile," SAE 670050,<br />
4. Hashimoto. F. "Model<strong>in</strong>g and Optimization of<br />
Vibratory F<strong>in</strong>ish<strong>in</strong>g Process," Annals of CIPP,<br />
Vol. 45, January 1.996.<br />
5. Simpson. R . and R. Garibay .."Quantification of<br />
Shot Peen<strong>in</strong>g Process Variables Affect<strong>in</strong>g<br />
Workpiece Performance-Process Control. and<br />
Double Shot Peen<strong>in</strong>g Medi.a," SAE-8507'14.<br />
lal15x Case microstructure to exam<strong>in</strong>elempered<br />
rna rte nsite and reta<strong>in</strong>ed a ustenite. 500~.<br />
Etchant4% Nital.<br />
This artlcle was fiirst Ipublished <strong>in</strong>tbe'<br />
P,roceed<strong>in</strong>gsohhe International Conference 'on<br />
Mechanicall Transmissions. heidi <strong>in</strong> Apr:il 20011<br />
<strong>in</strong> Chongq<strong>in</strong>g •.th<strong>in</strong>a ..<br />
(b) 500x Core microstructure to exam<strong>in</strong>e temper,ed<br />
martensite and some trans<strong>format</strong>ion products.<br />
500x. Etcha lit 4% Nilai.<br />
Tell Us Mat Youn<strong>in</strong>k ...<br />
VISit www,,,'lfIChnDlogy.comto<br />
• Rate this article<br />
• Request more <strong>in</strong><strong>format</strong>ion<br />
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Ie) 1.0Ci0x<br />
SEM photographs show<strong>in</strong>g <strong>the</strong> pit exam<strong>in</strong>ed.<br />
Intergrannlar oxidation and <strong>in</strong>clusion examl'<br />
nation nea r ha rdened case area.<br />
5OOx. Etchan! 2% Nital.<br />
Figure l1-Typical microstructure photograph of tested parts.<br />
www.pow8rlran$mission.com' www.geartechnoiDgy.com ,. GEAR TECHNOLOGY' JULY/AUGUST <strong>2002</strong> 25
Performance Analysis of<br />
Hypoid <strong>Gear</strong>s by Tooth Flank<br />
- Form Measurement<br />
IRyohei Takeda, Zhonghou Wang,<br />
Aizoh Kubo, Soichi,rC1Asano and Shogo, Kato<br />
ihis<br />
presented<br />
pape.f was<br />
al<strong>the</strong><br />
JSME International<br />
Iransmissiuns,<br />
Conference, on<br />
Motion and Power<br />
MP12001,<br />
<strong>in</strong> Fukuoka, Japan, l<strong>in</strong><br />
Po<strong>in</strong>t-te-Pc<strong>in</strong>t<br />
November 2001.<br />
Measurement<br />
Touch po<strong>in</strong>ts on <strong>the</strong> grid:;<br />
Pro!ile<br />
lengthwise<br />
5 po<strong>in</strong>ts<br />
9 'PQil!l$<br />
Introduction<br />
The traditional way of controll<strong>in</strong>g <strong>the</strong> quality<br />
of hypoid gears' tooth flank fonn is to check <strong>the</strong><br />
tooth flank contact patterns. But it is not easy to<br />
exactly judge <strong>the</strong> tooth flank fonn quality by <strong>the</strong><br />
contact pattern. In recent years,it has become<br />
possible to accurately measure <strong>the</strong> tooth flank<br />
form of hypoid gears by <strong>the</strong> po<strong>in</strong>t-to-po<strong>in</strong>t measur<strong>in</strong>g<br />
method and <strong>the</strong> scann<strong>in</strong>g measur<strong>in</strong>g<br />
method. But <strong>the</strong> uses of measured data of <strong>the</strong><br />
Figure I-Tile scann<strong>in</strong>g measur<strong>in</strong>g method of<br />
hypoid gears.<br />
x<br />
S·cann<strong>in</strong>g<br />
Yd = Constant<br />
Trace l<strong>in</strong>es:<br />
Scann<strong>in</strong>g<br />
:Profile Max.<br />
Lead Max.<br />
Measurement<br />
113 po<strong>in</strong>ts per l<strong>in</strong>e<br />
29Unes<br />
9 l<strong>in</strong>es<br />
been well developed <strong>in</strong> comparison with cyl<strong>in</strong>drical<br />
<strong>in</strong>volute gears. In this paper, <strong>the</strong> tooth flank<br />
form measurement of generated face-milled gears,<br />
face-bobbed gears and Formate®/generated gears<br />
are reported. The authors discuss <strong>the</strong> advantages<br />
and disadvantages of scann<strong>in</strong>g and po<strong>in</strong>t-to-po<strong>in</strong>t<br />
measur<strong>in</strong>g of 3-D tooth flank forms of hypoid<br />
gears and <strong>in</strong>troduce some examples of uses of<br />
measured data for high-quality production and<br />
performance prediction.<br />
Polnt-To-Pu<strong>in</strong>t or Scann<strong>in</strong>g Measurement<br />
The tradi tional measur<strong>in</strong>g method for <strong>the</strong> tooth<br />
flank form of hypoid gears is carried out by po<strong>in</strong>tto-po<strong>in</strong>t<br />
measurement us<strong>in</strong>g coord<strong>in</strong>ate measur<strong>in</strong>g<br />
mach<strong>in</strong>es (CMMs). That method is used to avoid<br />
<strong>the</strong> effect of friction between <strong>the</strong> 3-D sensor probe<br />
and tooth flank surface on <strong>the</strong> measured result.<br />
Recently, a reliable measur<strong>in</strong>g method by scann<strong>in</strong>g<br />
<strong>the</strong> objective tooth flank has been realized,<br />
The scann<strong>in</strong>g measur<strong>in</strong>g mach<strong>in</strong>e, as shown <strong>in</strong><br />
Figure I, uses a 2-D sensor. The negative <strong>in</strong>fluence<br />
of tooth flank friction on <strong>the</strong> measured<br />
results is avoided by control of rotation of <strong>the</strong> z-<br />
axis and by parallel movement of <strong>the</strong> sensor head<br />
position consider<strong>in</strong>g <strong>the</strong> sensitivity direction of<br />
<strong>the</strong> sensor probe and <strong>the</strong> scann<strong>in</strong>g direction of <strong>the</strong><br />
tooth flank (Ref. 1).<br />
Figure 2 shows how those two k<strong>in</strong>ds of measurernentare<br />
performed. A typical po<strong>in</strong>t-to-po<strong>in</strong>t<br />
measur<strong>in</strong>g pattern is a 5 x 9 grid of <strong>the</strong> loath flank.<br />
These measur<strong>in</strong>g po<strong>in</strong>ts usually exist well <strong>in</strong>side<br />
<strong>the</strong> tip and side edges of <strong>the</strong> objective tooth flank.<br />
Us<strong>in</strong>g <strong>the</strong> scann<strong>in</strong>g measur<strong>in</strong>g method, edge-toedge<br />
measurement is possible ..That measurement<br />
covers all of <strong>the</strong> tooth flank area, <strong>in</strong>clud<strong>in</strong>g <strong>the</strong><br />
tooth tip and <strong>the</strong> area near <strong>the</strong> toe and heel. The<br />
scann<strong>in</strong>g measur<strong>in</strong>g mach<strong>in</strong>e that <strong>the</strong> authors have<br />
developed can <strong>in</strong>corporate various measur<strong>in</strong>g patterns.<br />
For example. to simulate gear performance,<br />
a pattern of 29 l<strong>in</strong>es of profile and one l<strong>in</strong>e of lead,<br />
Figure 2-Two k<strong>in</strong>ds of measur<strong>in</strong>g methods for lIypoid gears. or a pattern of three l<strong>in</strong>es of profile and three l<strong>in</strong>es<br />
26 JULY/AUGUST <strong>2002</strong>' GEAR TECHNOLOGY. www.geartechnology.com· www.powartransmission.com
of lead are usually <strong>in</strong>corporated,<br />
Each l<strong>in</strong>e has<br />
Inmeasur<strong>in</strong>g po<strong>in</strong>ts.<br />
Figure 3 compares data of a tooth flank 'form<br />
measured by boih <strong>the</strong> scann<strong>in</strong>g and po<strong>in</strong>t-to-po<strong>in</strong>t<br />
method. The objective 100111 Hank form has<br />
some wav<strong>in</strong>ess (high-frequency components).<br />
That wav<strong>in</strong>ess was found (0 be <strong>the</strong> ma<strong>in</strong> cause of<br />
unpleasant gear noise, The scann<strong>in</strong>g method, can<br />
detect <strong>the</strong> detail of a tooth flank form. but <strong>the</strong><br />
po<strong>in</strong>t-to-polnt method could not do so.<br />
Two K<strong>in</strong>ds 'Of Method-.S 110 Defme<br />
Reference Tooth Su-.rface<br />
Direct approacf' (Machir"e' setl<strong>in</strong>g base],<br />
Exist<strong>in</strong>g CMMs normally <strong>in</strong>corporate <strong>the</strong> nom<strong>in</strong>al<br />
surface calculated by cutt<strong>in</strong>g mach<strong>in</strong>e sett<strong>in</strong>g<br />
parameters and cutter geometry for both r<strong>in</strong>g gear<br />
and p<strong>in</strong>ion as <strong>the</strong> reference surface to def<strong>in</strong>e tooth<br />
flank: form deviation. It is good <strong>in</strong> practice 1:0<br />
check whe<strong>the</strong>r <strong>the</strong> tooth cutt<strong>in</strong>g i performed CO[-<br />
reetly 01' not. But hypoid gears are heat treated,<br />
usually case hardened, and <strong>the</strong>n lapped. Aller<br />
heat treatment or lapp<strong>in</strong>g. tooth surfaces are distorted<br />
or deformed from that of <strong>the</strong> cutt<strong>in</strong>g stage,<br />
That mean gears have lost <strong>the</strong>ir datum and it is<br />
<strong>the</strong>refore often not useful to mea lire <strong>the</strong> tooth<br />
flank form deviation of hypoid gears accord<strong>in</strong>g to<br />
<strong>the</strong> reference based on We mach<strong>in</strong>e sett<strong>in</strong>g.<br />
Conjugate app.roach. In <strong>the</strong> case of <strong>the</strong> scann<strong>in</strong>g<br />
method. <strong>the</strong> reference tooth surface of r<strong>in</strong>g<br />
gears is calculated by cutt<strong>in</strong>g mach<strong>in</strong>e sett<strong>in</strong>g<br />
parameters just like tile former case ..However, for<br />
<strong>the</strong> p<strong>in</strong>ion, <strong>the</strong> conjugate surface to <strong>the</strong> r<strong>in</strong>g gear<br />
urface i u ed, Inthis case, two reference surfaces<br />
can rotate <strong>the</strong>oretically without motion<br />
error.<br />
The conjugate surface of <strong>the</strong> p<strong>in</strong>ion i a virtuaJ<br />
one. If l1Iep<strong>in</strong>ion and gear teeth are measured<br />
5.5 fz component<br />
IOrd.r tQllb mesb<strong>in</strong>g '1rI!1(!!!mcy<br />
us<strong>in</strong>g such a conjugate approach. <strong>the</strong> measured Tooth Contact Anal,ysis Under No Load<br />
values of <strong>the</strong> flank form deviation would show Conventionally. tooth contact a.naJysis (TCA)<br />
how far <strong>the</strong> form is from its true surface. which of hypoid gear is performed us<strong>in</strong>g tooth surface<br />
would realize conjugate motion. Tile same is true geometry calculated by <strong>the</strong> tooth cutt<strong>in</strong>g mach<strong>in</strong>e<br />
,j'I'~"... ,...<br />
i..".... .r....... '\<br />
F •So.., .. olll'P .ib~<br />
- i"1 ... ,b:mpla o1 l lnullil~lti..<br />
,...4<br />
./ BySClnn<strong>in</strong>g rTJiI.sur<strong>in</strong>liimM;hi."<br />
,I) M,ul!rd res!!1101 vibration bllMeasu:rd curn ollootll "ID~:form<br />
Figure 3-Difjerence ill vibrational stale oj gears, IIIlIel.' tootll,jlallkjorm de vialUms<br />
base dlfjert!flt high frequency ,componelll • alld tile comparo.'Oll 0/ tootll<br />
fll1II1c/ormmeasured by poirlt-to-poillt "",d. canllirlg mel/mas/or ,'I,al ca_I!.<br />
Pr.m.<br />
nl., tOI<br />
Pnlfl'-I!'<br />
.ifd_,<br />
·widtbl<br />
Prom.<br />
I!U!11<br />
IhRI<br />
P<strong>in</strong>iQo1.<br />
W-h •• ll<br />
of cyl<strong>in</strong>drical <strong>in</strong>volute gears. That mean we can sett<strong>in</strong>g parameters for bothr:<strong>in</strong>g gear and p<strong>in</strong>ion.<br />
use <strong>the</strong> experience of cyl<strong>in</strong>drical <strong>in</strong>volute gears Figure 6(a) hews an example of tooth contact<br />
for design<strong>in</strong>g and manufactur<strong>in</strong>g hypoidgears, analy is of Gleason Hehxform® hypoid gears<br />
and <strong>the</strong> measured data of <strong>the</strong> gear el can be used (gear et 1 shown <strong>in</strong> Table I) by direct approach<br />
at any stage of design<strong>in</strong>g or manufactur<strong>in</strong>g. (Gleason TCA). Us<strong>in</strong>g <strong>the</strong> concept of <strong>the</strong> conjuis<br />
president<br />
of Asmlo <strong>Gear</strong><br />
Direct' pred.iclioll of contact pat.tern gate tooth flank forms of mat<strong>in</strong>g gears and com- Co. ua.. of Osaka. Japan.<br />
from measured reslIlts. Figure 4 shows an po ite error surface (Ref. 2). a simulation pro- which manufactures Mears<br />
example of <strong>the</strong> output forms of measured results gram for predict<strong>in</strong>g <strong>the</strong> gear performance was and gear unhs.<br />
from <strong>the</strong> conjugate approach for a Forma!.e® developed. Figure 6(b) is an example of <strong>the</strong> out- Dr; Shogo Kato<br />
hypoidgear set. Here, <strong>the</strong> r<strong>in</strong>g gear's measured put of simulated results by conjugate approach I.r senior 1'f'.W!IJr'C'h('r ill<br />
curve i hown by sen<strong>in</strong>git to <strong>the</strong> po Won of coo- for <strong>the</strong> same gears under tile same condition. The Asalla <strong>Gear</strong>'s eIIR;t1eer;'lg<br />
department. 1/1 1979. he<br />
tact correspond<strong>in</strong>g to thaI of <strong>the</strong> measured p<strong>in</strong>ion. results of (a) and. (b) agree well, when <strong>the</strong> same<br />
lie veloped pr<strong>in</strong>ciples for<br />
Because <strong>the</strong> conjugate p<strong>in</strong>ion: tooth flank form is mount<strong>in</strong>g position (VIH valuerts given. 1001/1 profile m1.'fISIIYI.'m1'11I<br />
<strong>in</strong>corporated for reference <strong>in</strong> def<strong>in</strong><strong>in</strong>g <strong>the</strong> tooth of hypoiti gears.<br />
www.powerl,ansmlssion.com •.. W .... gfN.,rschnology.com '. GEAR TECHNOLOGY' JULY/AUGUST <strong>2002</strong> .27<br />
~nr!! __•<br />
1•• 1b<br />
".nk ,Dr<br />
wh •• r<br />
ICooe ...<br />
loath<br />
;F:...::.,,:lrltt- 'It,nk 0'<br />
pl.lo.<br />
P,<strong>in</strong>ion t,<br />
Wh •• 11]<br />
Figur:e 4-Measul'ed tooti. profill! alld teod [ormo[ Gleason jace-milled,<br />
Fiirmale@lgenerated gear set expressed ;n malill,g state.<br />
see <strong>the</strong> outl<strong>in</strong>e of <strong>the</strong> tooth flank contact pattern.<br />
Measurement of <strong>Gear</strong>s from DLfIcR!ol Tooth<br />
Cutt<strong>in</strong>g Methods<br />
The scann<strong>in</strong>g method is capable of measur<strong>in</strong>g<br />
tooth flank form deviation of hypoid gear be<strong>in</strong>g<br />
cut by different cutt<strong>in</strong>g methods, igure 5(a)<br />
shows a sample of measured results (rom a generated<br />
face-milled gear set. and Figure 5(b) shows<br />
that of a face-bobbed spiral bevelgear set.<br />
Ryohei Takedal<br />
flank form deviation, every po.<strong>in</strong>l on both curves<br />
. f is {/ general manager ill rile<br />
corresponds to contact. From this presentation or<br />
system eng<strong>in</strong>eer<strong>in</strong>g dept/rimea<br />
ured re ul • we <strong>the</strong>refore can directly see i1If'!l! (if Osako Seimil.fll<br />
<strong>the</strong> contact position of tooth flank of actual gears Kiwi Co. Ltd .. Jocml'd ill<br />
on <strong>the</strong> measured curves=that is. we can directly Osaka. Japo». HI' is ill<br />
ciJarge of technical del·elop·<br />
melll nJ <strong>the</strong> ('atfl{)(.III_~1$ sear<br />
measur<strong>in</strong>g mach<strong>in</strong>es.<br />
Dr. Zhonghou<br />
w.ang<br />
i.f a consultant for Nihon<br />
Parametric Technology I(.K.<br />
of Tokyo. As (l doctoral studau.<br />
Ire did a Sillily on perfonnance<br />
anotysis ana simu-<br />
/mimr of ttypoid Rears.<br />
Prof. Dr.<br />
Eng ..Aizoh Kl.lbol<br />
belol1gs to tht! jacullY at<br />
Kyoto Univer. iry, 1£l{'alt!d ill<br />
Kyoto. Japan. He 'l'or.b <strong>in</strong><br />
<strong>the</strong> precision eng<strong>in</strong>eerillg<br />
deportment. w/rk/l.l<strong>in</strong>rll/ares<br />
tlu: lJeifomrance of<br />
In·IJUidlbel·e/ gems.
al·GI.....<br />
~f<br />
~lLJ<br />
'.::<br />
No,. 01 teeth:<br />
\ tll,l'll<br />
~ M':!~I.'<br />
,,~ hce Width:<br />
".lV· : 25.0mm<br />
.. P<strong>in</strong>ion Ofbet<br />
_ 5jt mill<br />
"<strong>in</strong>al •• at PLniQP<br />
:gan.raled/generated hnoid gelt<br />
p...m.<br />
r••!fiLud<br />
''li-i"'tr.<br />
" \<br />
Figure 5 Measured tooth ./klnk form of gears of different cutt<strong>in</strong>g met/JOds.<br />
Tooth contllc': pattern<br />
!Motion CUIflI8<br />
-.,..... _',L--<br />
Vill., ..IJ.~1.13 (mm)<br />
a) Direct appr,olch (Gleason TCA)<br />
Figure 6-TCA<br />
.::.,<br />
r.,l,\~~ ....<br />
1/.: ~;"<br />
'If! ~<br />
it<br />
C~ntaclP.lttem<br />
1"--- ... -<br />
! j TraR.mission Errllf<br />
j __ M~~<br />
AI. <strong>the</strong> first stage of hypoid<br />
cutt<strong>in</strong>g<br />
28 JULY/AUGUST <strong>2002</strong>· GEAR TECHNOLOGV • www.geartschnology.com' wwW.powsftransm/ss/on.com<br />
..<br />
~ liiim~':J;<br />
! u - -<br />
• --':11 !I' -, -<br />
-------'<br />
ViIl,= ..1),081'1.'13 (mm)<br />
of direct approach amI conjugaleappr:oach.<br />
.,<br />
..<br />
..<br />
..<br />
..<br />
Contac! Pattern & Plm 01ColIIId<br />
., ; II<br />
J J<br />
/"<br />
r /<br />
of F F<br />
... ..<br />
"<br />
fI Trusm'ission' Enor<br />
(Too.h Harmonics)<br />
u<br />
IJ<br />
u<br />
u<br />
u<br />
1-'<br />
.....-<br />
OJ •<br />
Figure "" Simuiatio.n! for pillio/l CUttilig ehang«<br />
(conjugate approacll).<br />
I<br />
gear development,<br />
mach<strong>in</strong>es for p<strong>in</strong>ion teeth are adjusted to<br />
get <strong>the</strong> optimum tooth contact pattern as seen <strong>in</strong><br />
Figure 6(b). Figure 7 shows <strong>the</strong> simulated effect<br />
of a change <strong>in</strong> p<strong>in</strong>ion cutt<strong>in</strong>g conditions. In this<br />
case, a 60' bias-<strong>in</strong> change is given accord<strong>in</strong>g to'<br />
<strong>the</strong> Gleason cutt<strong>in</strong>g sheet (Summary).<br />
By this change, <strong>the</strong> path of contact (<strong>the</strong> trace<br />
of dots <strong>in</strong> <strong>the</strong> figure) is <strong>in</strong>cl<strong>in</strong>ed and <strong>the</strong> contact<br />
pattern becomes longer, but <strong>the</strong> contact position<br />
is shifted <strong>in</strong> <strong>the</strong> toe direction .. In this case, <strong>the</strong><br />
mount<strong>in</strong>g position should <strong>the</strong>refore be adjusted to<br />
get <strong>the</strong> contact. pattern. <strong>in</strong> <strong>the</strong> middle<br />
of <strong>the</strong> moth<br />
Hank.<br />
Tooth Contact Analysis of Actual <strong>Gear</strong><br />
Us<strong>in</strong>g <strong>the</strong> conjugate approach, tooth contact<br />
analysis of actual hypcid gears based on <strong>the</strong><br />
measured tooth flank form data becomes easy.<br />
An example of analysis of acrualgears that had<br />
tooth wear problems <strong>in</strong> <strong>the</strong> field is discussed <strong>in</strong><br />
<strong>the</strong> fol1ow<strong>in</strong>g sections.<br />
No load analysis. The sample<br />
gear set used<strong>in</strong><br />
Figures 8-10 is gear set 2 il] Table 1. Figure 8(a)<br />
shows <strong>the</strong> composite error surface for <strong>the</strong> <strong>the</strong>oretical<br />
tooth flank form calculated<br />
from. <strong>the</strong> mach<strong>in</strong>e<br />
sett<strong>in</strong>g parameters for r<strong>in</strong>g gear and p<strong>in</strong>ion. That<br />
surface is expressed by <strong>the</strong> form deviation curve<br />
on each contact l<strong>in</strong>e, neglect<strong>in</strong>g its actual length.<br />
The contact l<strong>in</strong>es are set <strong>in</strong> <strong>the</strong> direction of <strong>the</strong><br />
progress of gear mesh and <strong>the</strong> composite error<br />
values are plotted on <strong>the</strong>se contact l<strong>in</strong>es. The<br />
length of contact l<strong>in</strong>e near toe and heel of a tooth<br />
is stretched, which differs from <strong>the</strong> actual state ..<br />
But by this expression, <strong>the</strong> contact po<strong>in</strong>t of tooth<br />
flanks can be more vividly recognized. The effect<br />
of toprem® is well recognized from <strong>the</strong> figure ..<br />
Toprem® is a protuberance on <strong>the</strong> hypoid cutt<strong>in</strong>g<br />
blade that produces an undercut on <strong>the</strong> gear be<strong>in</strong>g<br />
cut.<br />
FCQm Figure 8(a), we can directlypredict <strong>the</strong><br />
contact pattern under no-load conditions to some<br />
extent, Figures 8(b) and 8(c) show <strong>the</strong> path-ofcontactpe<strong>in</strong>t<br />
and contact pattem expressed on <strong>the</strong><br />
r<strong>in</strong>g gear tooth flank under no load. Figure 8Cd)<br />
shows <strong>the</strong> motion curve (transmission error) for<br />
this case,<br />
This gear set has experienced trouble with<br />
tooth flank wear. Figure '9 shows <strong>the</strong> state of <strong>the</strong><br />
<strong>in</strong>itial tooth flank, l.e. of fresh gears just produced,<br />
<strong>in</strong> terms of measured composite error surface,<br />
observed no-load contact pattern obta<strong>in</strong>ed<br />
on <strong>the</strong> mesh<strong>in</strong>g frame (roll<strong>in</strong>g tester) and<strong>the</strong> noload<br />
contact pa:ttern calculated by us<strong>in</strong>g <strong>the</strong> measured<br />
tooth flank form data (Ref. 4). The transmission<br />
error calculated for no-load conditions by
us<strong>in</strong>g measured tooth flank: form is also hown.<br />
Figure ]0 shows those aspects for <strong>the</strong> worn tooth<br />
Han~ of <strong>the</strong>troubled gear . U ually <strong>the</strong> mount<strong>in</strong>g<br />
po ition of hypoid gears, normally expressed by<br />
(V, H) value, is different at lapp<strong>in</strong>g, at <strong>the</strong> loath<br />
contact pattern check<strong>in</strong>g on a roll<strong>in</strong>g tester. and <strong>in</strong><br />
an actual gearbox's assembled! condition. This difference<br />
leads to <strong>the</strong> same k<strong>in</strong>d of difficulty <strong>in</strong> carry<strong>in</strong>g<br />
out <strong>the</strong> simulation us<strong>in</strong>g <strong>the</strong> measured data<br />
of tooth flank form deviation of hypoid gears. In<br />
<strong>the</strong> simulation. some adjustm.ent of (V, H} values<br />
from 'those nom<strong>in</strong>al mount<strong>in</strong>g di Lances (V n' "0)<br />
at design<strong>in</strong>g or 011 <strong>the</strong> roll<strong>in</strong>g tester is usually necessary<br />
to obta<strong>in</strong> <strong>the</strong> nearest contact pattern<br />
between observed and imnlated figures.<br />
On loa.d an.alysis. Figure 11 shows <strong>the</strong> comparison<br />
between <strong>the</strong> mea ured and simulated contact<br />
patternunder load, and<strong>the</strong> transmission error<br />
for that case. Figure l 2 shows <strong>the</strong> distribution of<br />
normal load. flash temperature {a), and Hertzian<br />
stress on <strong>the</strong> tooth flank,<br />
Flash temperature T f (<strong>in</strong> degree ) is obta<strong>in</strong>ed as<br />
a function of <strong>the</strong> flash temperature <strong>in</strong>dex Tr* by<br />
<strong>the</strong> follow,jng equation:<br />
T, = Til' (U 1~ ..J1t .. rpm/30) /..J A . P . c,<br />
where ~. = functional coefficient of tooth flank;<br />
rpm"" rotational speed of p<strong>in</strong>ion; A = normal conductivity;<br />
p = specific weight; and c = specific<br />
heat.<br />
The sample gear set \I ed <strong>in</strong> Figures 11 and ] 2<br />
i gear et 3 <strong>in</strong> Table 1. Figure 13 compare <strong>the</strong><br />
. imulated, FEA calculated and measured tooth fillet<br />
stre s (Ref. 6) for gear et 4 from Table 1.<br />
FigureI3(a) hows <strong>the</strong> chang<strong>in</strong>g stale of tooth fillet<br />
stress with <strong>the</strong> progress of mesh<strong>in</strong>g at three<br />
longitud<strong>in</strong>al fillet positions along <strong>the</strong> tooth width,<br />
i.e. at 116 from toe, 1/2 from toe and 5/6 from 'toe.<br />
Figure l3(b) arranges <strong>the</strong> same resultsm <strong>the</strong><br />
form of fillet stress distributionalong looth widlh.<br />
These figures for tooth fillet stress showa good<br />
agreement among<strong>the</strong><br />
FHA., mea ured and simulated<br />
results. Figure 14 shows a simulated frequency<br />
component of vibrational excitation for<br />
gear set 2 <strong>in</strong> Table 1. us<strong>in</strong>g measured tooth flank<br />
form deviation of <strong>the</strong> <strong>in</strong>itial gear flanks shown <strong>in</strong><br />
Figure 8. The vtbrational excitation is calculated<br />
<strong>in</strong> terms of <strong>the</strong> tooth mesh<strong>in</strong>g frequency components.<br />
The actual frequency component <strong>in</strong> Hem<br />
(lIs) of <strong>the</strong> vibrational excitation caused by <strong>the</strong><br />
tooth me h<strong>in</strong>g of <strong>the</strong>se hypoid gears can be well<br />
predicted from <strong>the</strong>se results and <strong>the</strong> driv<strong>in</strong>g speed<br />
of this gear set <strong>in</strong> operation, AIl of <strong>the</strong>se quantities.<br />
concern<strong>in</strong>g <strong>the</strong> performance of gears aresimulated-calculatedat<br />
tile same time. This is an extraor-<br />
F.igul'e tJ-Composite e17'Orsurj'ace, path: o/,contaci po<strong>in</strong>t and red COl/tad paltem<br />
,expressed ,011 <strong>the</strong> r<strong>in</strong>g gear tootll.JlaJlk (JOT geaTS cut by standard mach<strong>in</strong>e<br />
settiJlg summary data, and V=O.OO mm, H=O.OO rnm).<br />
.Figur-e 9-Composite<br />
jlrmk,<br />
-<br />
..'~""'---<br />
Figure UJ-Composite<br />
e",or<br />
.,-' -".....<br />
(V!I! N~, '.. I<br />
!V--'....""I<br />
troubled gears ..<br />
.,....,-".....--<br />
.....----<br />
....<br />
Uh A A I<br />
lit~~~<br />
---<br />
, , .<br />
.,-.. ..... _ .. I00
_I·Simul"t.dl<br />
•• llt1l., 'potlom<br />
I<br />
I . 1<br />
i t.-------+--'t---I---''r-+----'<br />
~<br />
I<br />
:L:'---------<br />
PROURE$$ OF M~SHING<br />
d Simul.ted IrlIn.miui .... "'"<br />
..,de, 10 d<br />
Figure.11 LJaded contact pattern OIl r<strong>in</strong>g gear flank and tile transmission<br />
error (<strong>in</strong>pllt torque » 30 N-m).<br />
gears that can accept measured form deviation of<br />
real tooth flank form is developed. The gear performance-such<br />
as transmission error, contact<br />
pattern under load and no load, normal loa.d<br />
distribution on tooth flank, contact stre ,tooth<br />
fillet stress, flash temperature and vibrational<br />
excitation for actual production gears-can now<br />
be analyzed. Some simulated results are compared<br />
with actual results <strong>in</strong> <strong>the</strong> field and from<br />
experience. Also, <strong>the</strong> effectiveness of <strong>the</strong> measurement<br />
of tooth flank form accuracy of hypoid<br />
gears is discussed. 0<br />
Figure l2-Simulaled<br />
l60<br />
stress stale on tooti:flank of lJypoid gears.<br />
-.-FU<br />
---+---- A.ppnmmlloa<br />
- ..........<br />
It 116<br />
(I) Compoo:i... am""l FEA. M ....... d ..,d ,oI',ulll,d<br />
fiUet strcs! distributiQf1 with 'tJ:K prog.tcu of mesh<strong>in</strong>g<br />
Figure 13 R<strong>in</strong>g gear .tooth fillet stress (torque s» 777 Nvm).<br />
e<br />
~ 6<br />
e<br />
.g<br />
,l!<br />
'u<br />
11&1 'I<<br />
c<br />
Abscissa is <strong>the</strong> order<br />
tOI Imesh<strong>in</strong>g freq,uency<br />
Figure U-Remlt ,of<strong>the</strong> vibrational ,excitation.<br />
e<br />
~<br />
Ie<br />
<br />
".c:<br />
.~ u<br />
~<br />
e<br />
Q<br />
'1i<br />
.0<br />
:> WEAR SiAGE<br />
o 0..2 0.4 0.6 0,8 1<br />
Toe:<br />
Becl<br />
(b) Coolp.ri..,.. __ !'EA. M.U1Dd oM 'oimuI.lt.,d<br />
maximum, fillet WCI.I distribution at ODJ toodl width<br />
Figure 15-Cllallge of <strong>the</strong> mesh iug frequellcy COlllpO'l.lelltof Jlibratiollal excitation<br />
willi:progress of tootiJ flank wear.<br />
References<br />
I. Saito, Y. er al. "Check of 3D Fonn Aocuracy of<br />
Hypoid & Bevel <strong>Gear</strong> Teeth for <strong>the</strong> New Generation of<br />
Quality Contra]," AGMA Fall Technical Meet<strong>in</strong>g, 1.998.<br />
2. Kubo, A. et al, "A Computer Based Approach for<br />
Evaluation of Operat<strong>in</strong>g Performance of Bevel and<br />
Hypoid <strong>Gear</strong>s," lSME International Journal (Series<br />
C), Vol.40, No.4, 199'7,pp. 749-758.<br />
3.. Kagimoto, H.et al, "Development of Tooth<br />
Surface Measur<strong>in</strong>g Mach<strong>in</strong>e for Hypoid <strong>Gear</strong>s,"<br />
Toyota Motor Co. Technical. Review, Vol. 43, No. L<br />
May 1993,pp. 112-1l7.<br />
4. Wang, Zhonghou, A. Kubo.et aI. "Simulation of<br />
Deterioration of Hypoid <strong>Gear</strong> Performance due to<br />
Tooth Flank Wear (I st Report, Data Process<strong>in</strong>g of<br />
Measured Tooth Flank Wear)," Transactions of <strong>the</strong><br />
Japan Society of Mechallical Eng<strong>in</strong>eers, Vol.66. No.<br />
647, 2000, pp. 2354-2362.<br />
5, Wallg, Zhonghou, A. Kubo et al, "Simulation of<br />
Deterioration of Hypoid <strong>Gear</strong> Performance due 10<br />
Tooth flank Wear (2nd Report. Model for Tooth flank<br />
Wear and <strong>the</strong> Change ofGerur Performance Resulted},"<br />
Transactions of <strong>the</strong> Japan Society of Mechanical<br />
Eng<strong>in</strong>eers, Vol.66, No. 647. 2000, pp. 2363-2370,<br />
6. Wang. Zhonghou, A. Kubo et al. "Tooth Root<br />
Stress Analysis of Hypoid <strong>Gear</strong>s (2nd Report,<br />
Introduction of Predict<strong>in</strong>g Method. for <strong>the</strong> Tooth<br />
Root)," Transactions of <strong>the</strong> Japan Society of<br />
Mechanical Eng<strong>in</strong>eers, Vol. 66, o. 652, December<br />
2000, pp. 221-227.<br />
7, Wang, Zhonghou, A. Kubo et al. "Measurement of<br />
3D Tooth flank Form of Hypoid <strong>Gear</strong>s and its Usage<br />
for High Quality Production and Performance<br />
Prediction," International Conference on Mechanical<br />
Transmissions, Chongq<strong>in</strong>g, Ch<strong>in</strong>a, April 200 1.<br />
Figures <strong>in</strong> Fig. 6,Fig. 7<br />
Which <strong>Gear</strong><br />
I Set Was Used<br />
I<br />
Fig. 8, Fig. 9,<br />
Fig. 10, Fig. 14<br />
Fig. 15<br />
Fig. II, Fig. 12 Fig. 13<br />
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30 JULV/AUGUST <strong>2002</strong> ., GEAR TECHNOLOGY' www.gearrechnology.com ., www.oowertrensmtsston.com
Sponsored by <strong>the</strong><br />
American <strong>Gear</strong> Manfacturers Association<br />
Greater Columbus Convention. Center<br />
Columbus, Ohio<br />
October 26 - 29,2003,
_-------------'INDUSTRYNIEWS-------------.<br />
Gleason Corp', Appo<strong>in</strong>ts Vi,ce<br />
President and CFO<br />
John 1. Perrotti was named executive<br />
vice president and CFO of Rochester,<br />
Nr-based Gleason Corp.<br />
He has been with Gleason s<strong>in</strong>ce 1986<br />
<strong>in</strong> a variety of positions and has served<br />
on <strong>the</strong> board of directors s<strong>in</strong>ce 2000.<br />
Perrotti holds memberships <strong>in</strong> several<br />
professional organizations, <strong>in</strong>clud<strong>in</strong>g <strong>the</strong><br />
Association for Manufactur<strong>in</strong>g Technology<br />
and <strong>the</strong> F<strong>in</strong>ancial Executives<br />
Institute. A CPA. he has degrees from <strong>the</strong><br />
University of Rochester and Rochester<br />
Institute of Technology.<br />
!Mahr Federal Appo<strong>in</strong>ts New VP<br />
Mahr Federal Inc., of Providence,<br />
RI, appo<strong>in</strong>ted. Patrick Nugent as vice<br />
president of metrology systems ..<br />
Precision Made - Cost Effective<br />
One Statement with Two Objectives<br />
Dragon Precision Tools from Korea.<br />
Noticeable Different. Clearly Superior.<br />
DRAGON PRECISION<br />
TOOLS CO., LTD.<br />
Represented Exclusively <strong>in</strong> <strong>the</strong> USA by:<br />
440.331.0038<br />
21135 Lora<strong>in</strong> Road<br />
Fairview Park t OH 44126<br />
Fax: 440.331.0516<br />
http://www.gallenco.com<br />
http://www.dragon.co.kr<br />
32 JULY/AUGUST <strong>2002</strong> • GEAR TECHNOLOGY' www.geart·echITology.com' www.powerlraITsmisslon.com<br />
Nugent most recently worked <strong>in</strong> <strong>the</strong><br />
metrology systems customer solutions<br />
group for Mahr's parent company, Mahr<br />
GmbH of Gott<strong>in</strong>gen, Germany .. Prior to<br />
that, he served <strong>in</strong> numerous eng<strong>in</strong>eer<strong>in</strong>g<br />
capacities for Cumm<strong>in</strong>s Eng<strong>in</strong>e Co.<br />
Among his new responsibilities<br />
a. manufacturer of aero-<br />
Paul D, Lefitf space gearbox assemblies,<br />
mechanical actuators, detail gear<strong>in</strong>g<br />
and complex precision mach<strong>in</strong>ed<br />
components for commercial and military<br />
aircraft systems.<br />
Lefief has held numerous senior<br />
management positions [or defense and<br />
commercial manufactur<strong>in</strong>g companies,<br />
<strong>in</strong>clud<strong>in</strong>g Daiml.erCb1Ysler,<br />
One of Lefler's goals will be to ga<strong>in</strong><br />
additional market share <strong>in</strong> <strong>the</strong> United<br />
States, Europe and Asia.<br />
Caratron Industries Inc. has been a<br />
wholly-owned subsidiary of Belgiumbased<br />
BMT nv. s<strong>in</strong>ce 2000.<br />
are<br />
lead<strong>in</strong>g <strong>the</strong> systems' bus<strong>in</strong>ess development<br />
and fur<strong>the</strong>r<strong>in</strong>g profitable growth <strong>in</strong><br />
<strong>the</strong> North American marketplace.<br />
Philadelphia<br />
<strong>Gear</strong> !Hires New CFO<br />
Philadelphia <strong>Gear</strong><br />
Corp .., of Norristown, PA,<br />
hired Stephen<br />
Verger as<br />
CFO.<br />
Among his responsi-<br />
Step/len Vergel bilities will be lead<strong>in</strong>g an<br />
account<strong>in</strong>g, f<strong>in</strong>ancial analysis and treasury<br />
functions for <strong>the</strong> company. He also<br />
will design Philadelphia <strong>Gear</strong>'s evolv<strong>in</strong>g<br />
bus<strong>in</strong>ess model, which is focused on<br />
speciali zed gear aftermarket service and<br />
mar<strong>in</strong>e propulsion drives.<br />
For <strong>the</strong> past 23 years, Verget has<br />
worked as a f<strong>in</strong>ance leader at EJ.<br />
DuPont de Nemours of Wilm<strong>in</strong>gton. DE,<br />
<strong>in</strong> a number of roles, <strong>in</strong>clud<strong>in</strong>g CFO<br />
positions <strong>in</strong> agricultural biotechnology<br />
and advanced materials.<br />
New Presid'ent and 'CEON!amed at<br />
Caratron In.d'Ustr:ies<br />
Paul D. Lefief was<br />
named president and<br />
CEO of Caratron Industries<br />
Inc., of Warren, MI,
• INDUSTIRVNEWS _<br />
Bodycote,~sIlans<strong>in</strong>g Pilant Receives<br />
BorgWarner Certification<br />
80rgWamer Automotive of Chicago,<br />
a, selected Bodyeote of Lans<strong>in</strong>g, MI,<br />
for <strong>the</strong> Zero Defect Supplier Award for<br />
<strong>the</strong> second eonsecutive year. The award<br />
was presented at a recent ceremony <strong>in</strong><br />
Chicago. Bodycote Lans<strong>in</strong>g is an ISO<br />
9000-. 'OS 9000- and Ford Ql-appreved<br />
facility.<br />
Bodycote Lans<strong>in</strong>g specializes <strong>in</strong><br />
balch atmospheric heat. treat<strong>in</strong>g and salt<br />
pot processes. The facility also has an<br />
extensive vibratory eleen<strong>in</strong>g capability.<br />
A focus at <strong>the</strong> plant is Bodycote' proprietary<br />
ferritic nitrocarburiz<strong>in</strong>g proee ,<br />
called L<strong>in</strong>dure.<br />
The Lans<strong>in</strong>g plant is part of a fiveplant<br />
network <strong>in</strong> Michigan. Bodycote<br />
North America Inc. is a subsidiary of<br />
Bodycote International plc, located ill<br />
Macclesfield,<br />
England.<br />
INew Sales Manager for IGreg<br />
Allen Co.<br />
Janice Thoma was<br />
appo<strong>in</strong>ted ales and ourci:ng<br />
manager for <strong>the</strong> gear<br />
cutt<strong>in</strong>g tools product l<strong>in</strong>e<br />
of Greg Allen Co., located<br />
JQnic~ TlIol1llD <strong>in</strong> Fairview Park, OH.<br />
Her new re pon ibibties <strong>in</strong>clude manag<strong>in</strong>g<br />
and direct<strong>in</strong>g a nationwide network<br />
of sales representatives, and coord<strong>in</strong>at<strong>in</strong>g<br />
with global suppliers.<br />
For <strong>the</strong> past 22 years" Thomashas<br />
worked ia<strong>the</strong>gjebal gear tool <strong>in</strong>dustry ..<br />
S<strong>in</strong>ce 1994. she has been <strong>the</strong> U.S. sales<br />
eng<strong>in</strong>eer for David Brown <strong>Gear</strong> Tools of<br />
Huddersfield, U.K.<br />
Birchmer'e Capital and Wild'eir-<br />
Deem Buy M<strong>in</strong>er ,Centrifugal<br />
Cast<strong>in</strong>g Co.<br />
Miller Centrifugal Cast<strong>in</strong>g Co.<br />
(MCC), a foundry <strong>in</strong> Cecil, PAt was<br />
bought by Birehmere Capital L.P. of<br />
Pittsburgh, PAt and Wilder-Deem of<br />
New York, NY.<br />
MCC manufactures f<strong>in</strong>ish-mach<strong>in</strong>ed<br />
ferrous and non-ferrous centrifugal cast<strong>in</strong>gs<br />
for equipment manufacturers and<br />
throughoul North America. Additionally.<br />
it. is a supplier of copper-based centrifugal<br />
cast<strong>in</strong>gs, hav<strong>in</strong>g patented <strong>the</strong><br />
bimetallic cast<strong>in</strong>g process used <strong>in</strong> <strong>the</strong><br />
wonn gear bus<strong>in</strong>ess.<br />
Tile Birehmere fund targets acquisitionsm<br />
middle market manufactur<strong>in</strong>g,<br />
distribution, service and f<strong>in</strong>ancial companies.<br />
Wilder-Deem. is a f<strong>in</strong>ancial consult<strong>in</strong>g<br />
and <strong>in</strong>vestment firm whose o<strong>the</strong>r<br />
steel-related hold<strong>in</strong>g is Damascus Steel<br />
Cast<strong>in</strong>gs of New Brighton, PA.O<br />
rail U. What You .... <strong>in</strong>k .•.<br />
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A Defi<strong>in</strong>itive Snurcebuek<br />
f'o:rTransmission Engi<strong>in</strong>e,e:rs:<br />
PROCEEDINGS<br />
International Conferen,ce ,on G,ears<br />
Mun.ich, March 13-115,201)2. Two volumes. VDI-Berichte<br />
No. 1665, edited by VOIi Association of German Eng<strong>in</strong>eers,<br />
VOl Society for Development, Design, and Distribution.<br />
1198 pages, numerous figures and tables, <strong>format</strong> '1!4.B ems<br />
x 21 cms. ISBN 3-18-091665-6. List price 144.00€.<br />
More than 80 richly illustrated contributions from<br />
renowned Gierman and <strong>in</strong>ternational experts cover <strong>the</strong><br />
entire spectrum of design, construction and applicat<strong>in</strong>n<br />
'of all types of gears. These two volumes present <strong>the</strong> latest<br />
state of technology to' <strong>the</strong> expert reader <strong>in</strong> R&D,<br />
:<strong>in</strong>dustry and academia.<br />
VIOl Ver:lag<br />
Orders: VDI Verlag. Ms. P,etro,Koe<strong>the</strong>r.<br />
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E-Mail: pkoe<strong>the</strong>r@vdi-nachrichten ..com<br />
Website: hHp:/lwww.vdi-litera.tur.de<br />
SP'IRAL IBEVEIL GEARS'<br />
(Transmissi,ons ),<br />
••• _TECHIN!I,CAL CAIl:ENIDAR ••• _<br />
<strong>July</strong> 15-17-Powder MetaUurgy Basic Shert Cour e. Penn<br />
Stater Conference Center Hotel, State College, PA. This conference<br />
will focu on <strong>the</strong> history of PfM, different designs <strong>in</strong> compact<strong>in</strong>g<br />
tools, <strong>the</strong> use of s<strong>in</strong>ter<strong>in</strong>g <strong>in</strong> develop<strong>in</strong>g functional properties,<br />
<strong>in</strong>jection mold<strong>in</strong>g of metal powder, M-P[F standards. special<br />
tests for powders and <strong>the</strong> latest high-tech PIM technologies.<br />
$1.,125 lor APMI members and MP]F member company<br />
employees. $1,325 for nonmembers ..For more ia<strong>format</strong>ion, contact<br />
<strong>the</strong> Metal Powder Industries Federation by telephoneat<br />
(609) 452-7700 or by fax at (609) 987-8523.<br />
<strong>July</strong> lS-1'9-8asic <strong>Gear</strong> Manufactur<strong>in</strong>g Course. Daley<br />
College, Chicago, IL. Offer<strong>in</strong>g hands-on tra<strong>in</strong><strong>in</strong>g <strong>in</strong> gear<strong>in</strong>g and<br />
nomenclature, pr<strong>in</strong>ciples of <strong>in</strong>spection, gear manufactur<strong>in</strong>g<br />
methods, and hobblog and shap<strong>in</strong>g. Open to sales reps, technidans,<br />
executives, managers, mach<strong>in</strong>ists. quality managers and<br />
eng<strong>in</strong>eers. $650 tor AGMA members, $775 for nonmembers.<br />
For more <strong>in</strong><strong>format</strong>ion, contact AGMA by telephone at (703)<br />
684-0211 or bye-mail atjentress@agma.org.<br />
September 4--11-futernational Manufactur<strong>in</strong>g Technology<br />
Show. McConnick Place. Chicago, IL Spon ored by AM'T- The<br />
Association for Manufactur<strong>in</strong>g Technology. See our coverage on<br />
pages 12-18 or visit www.imtsnet.org.<br />
September 11-l3-Basic <strong>Gear</strong> Noise Short Coull'Se. Ohio<br />
State University. Columbus. OH. Attendees willlearn to design<br />
gears to m<strong>in</strong>imize <strong>the</strong> major excitations of gear noise, transmission<br />
error, dynamic friction forces and shuttl<strong>in</strong>g forces.<br />
Extensive demonstrations of special gear analysis software will<br />
take place, <strong>in</strong> addition to showcas<strong>in</strong>g of OSU gear test rigs.<br />
Participants are <strong>in</strong>vited to discuss <strong>the</strong>ir specific gear and transmission<br />
noise concerns, $1.2501. For moremforrnation, contact<br />
OSU by telephone at (614) 292-5860 or on <strong>the</strong> Internet at<br />
www.gearlab.org,<br />
Spiral & Straight Bevel <strong>Gear</strong> Manufactur<strong>in</strong>g.<br />
ICommercial to aircraft quality gear<strong>in</strong>g,<br />
Spur,.he!lical,spl<strong>in</strong>edi shafts, l<strong>in</strong>ternal & externa'll,<br />
shaved & ground gears, Spira'i bevel gr<strong>in</strong>d<strong>in</strong>g.<br />
IMidwest Transmissions ,81Reducers ..<br />
ISO comp'liiant.<br />
MIDWESTGEAR:'M. -'I. WE~.<br />
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Wa rren, MI 4I11III9<br />
CONTACT;<br />
ICRAIG D. ROSS<br />
-(586) 754-8923<br />
IfAX (586) 754~B926<br />
September 11-I3-Fundamentals of <strong>Gear</strong> Design. University<br />
Center for Cont<strong>in</strong>u<strong>in</strong>g Education, University of Wiscons<strong>in</strong>-<br />
Milwaukee. Milwaukee. WI. This course will provide attendees<br />
with a beg<strong>in</strong>n<strong>in</strong>g knowledge of modem gear system design and<br />
analysis. A knowledge of geometry, trigonometry and elementary<br />
algebra is required. $1.0195. For more <strong>in</strong><strong>format</strong>ion, contact<br />
<strong>the</strong> University Center for Cont<strong>in</strong>u<strong>in</strong>g Education by telephone at<br />
(414) 227-3100 or visit <strong>the</strong> center's web pages via<br />
www.uwm.edu.<br />
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• 1 TECHNOLOGY FOCUS<br />
M'i<strong>in</strong>'imizatioln of <strong>in</strong>-Process<br />
Corrosion of Aerospace <strong>Gear</strong>s<br />
Son 'Ng!uyen, .AI:i Manesh. Jim~ Reeves and Danny Mahan<br />
I<br />
Factors Level = "+"<br />
U<br />
Level =<br />
I<br />
A Condition Virg<strong>in</strong> Heclaimed<br />
I B Alloy Pyrowear 53 9310<br />
C HT Condition Carburized Core Materia.1<br />
I<br />
o Exposure Time 90 M<strong>in</strong>utes 30 M<strong>in</strong>utes<br />
I<br />
E Coolant Concentration 8% 1%<br />
F Coolant Temperature 150°F iO°F<br />
I G Coolant Type Syn<strong>the</strong>tic Soluble Oil<br />
A B C 0 E F<br />
1<br />
,<br />
·1 1 1 1 1<br />
·1 ·1 ·1 1 , ,<br />
,<br />
E"G I Hours to Initiation i<br />
., ., 1848 II<br />
., ., 1848<br />
! I<br />
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! '847<br />
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1 -1 ·1 ., 1 ·1 ·1 ., 1395 ,I I<br />
1 ·1 1 1 , -, ., ·1 1394 I<br />
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, I -, ·1 1392<br />
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·1 1 1 1 1 I ·1 -1 1220 I<br />
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., ·1 1 ·1 ·1 1 I ·1 1 1204 ;<br />
i<br />
Figure i-Partial Experimental Matrix With Screen <strong>in</strong>g<br />
Analy<br />
sis.<br />
36 JULY/AUGUST <strong>2002</strong> .' GEAR TECHNOLOGY" www.qe srtecnnotoqv.com » www.powerrransmission ..ccm<br />
,<br />
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i<br />
I<br />
1<br />
Intrnduction<br />
Carbon steels have primarily been used<br />
to manufacture aerospace gears due to <strong>the</strong><br />
steels' mechanical characteristics. An<br />
alloyed low carbon steel is easily casehardened<br />
to obta<strong>in</strong> a hard wear surface<br />
while ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g <strong>the</strong> ductile core characteristics.<br />
The microstructure achieved will<br />
accept <strong>the</strong> heavy load<strong>in</strong>g. shocks, and elevated<br />
temperatures that gears typically<br />
experience <strong>in</strong> applications. The carbon<br />
steel mach<strong>in</strong>ability allows for general<br />
mach<strong>in</strong><strong>in</strong>g practices to be employed when<br />
produc<strong>in</strong>g aerospace gears versus <strong>the</strong> more<br />
advanced metal removal processes<br />
required by sta<strong>in</strong>less and nickel-based<br />
alloys.<br />
As a consequence<br />
of us<strong>in</strong>g non-sta<strong>in</strong>less<br />
steel for gears, <strong>in</strong>-process corrosion<br />
(rust and chemical attack) of gears is possible<br />
dur<strong>in</strong>g <strong>the</strong> manufactur<strong>in</strong>g process.<br />
Surface corrosion of carbon steel gears and<br />
shafts can lead to unacceptable stress risers<br />
<strong>in</strong> <strong>the</strong> material if action is not taken to<br />
remove <strong>the</strong> surface pitt<strong>in</strong>g and neutralize<br />
<strong>the</strong> cause. Once <strong>the</strong> corrosion effect beg<strong>in</strong>s,<br />
it wilLI cont<strong>in</strong>ue to attack <strong>the</strong> gra<strong>in</strong> boundaries<br />
of <strong>the</strong> material. The result is reduced<br />
mechanical properties of <strong>the</strong> alloy that can<br />
lead to component failure at performance<br />
levels wel.lbelow typical operat<strong>in</strong>g conditions.<br />
Prior to this project. <strong>the</strong> corrosion problem<br />
was m<strong>in</strong>imized by <strong>the</strong> use of oil-based<br />
preservatives and rust-<strong>in</strong>hibit<strong>in</strong>g mach<strong>in</strong><strong>in</strong>g<br />
coolants. However, as <strong>the</strong> negative<br />
effect on exposed production workers and<br />
<strong>the</strong> environment was better understood,<br />
and with disposal costs escalat<strong>in</strong>g, <strong>the</strong> gear<br />
manufactur<strong>in</strong>g <strong>in</strong>dustry changed to waterbased<br />
coolants and degreas<strong>in</strong>gagents. This
lion<br />
shift was i.mmediately followed by an<br />
<strong>in</strong>crease i.nrust. The result was more eostly<br />
gears from <strong>in</strong>creased rework, scrapped<br />
gears. <strong>in</strong>creased preventative activities and<br />
manufactur<strong>in</strong>g How <strong>in</strong>efficiencies due to<br />
out-or-sequence proces <strong>in</strong>g. The replacement<br />
of corroded gears created additional<br />
delays. Corrosion of gears <strong>in</strong> <strong>the</strong> manufaenir<strong>in</strong>g<br />
environmem cont<strong>in</strong>ued to plague <strong>the</strong><br />
entire gear <strong>in</strong>dustry; '<strong>the</strong>refore an <strong>in</strong>vestigation<br />
to m<strong>in</strong>imize !he corrosive effect was<br />
warranted.<br />
Olljootives<br />
The objective ' of !hi project were to<br />
identify <strong>the</strong> root causes of <strong>the</strong> observed <strong>in</strong>process<br />
corrosion<br />
of gears and to develop<br />
preventative practices to mitigate its occurrenee<br />
dur<strong>in</strong>g <strong>the</strong> manufactur<strong>in</strong>g of gears.<br />
Specifically. me objectives were:<br />
• Utilize advanced manufactur<strong>in</strong>g tools,<br />
uch as tati tically designed experiments,<br />
process How charts. and failure modes and<br />
effect analysi (FMEA) to systematically<br />
md'y <strong>the</strong> potential causes of <strong>the</strong> <strong>in</strong>-process<br />
cerro ion ..<br />
• Evaluate <strong>the</strong> impacts of chemical attack<br />
and residual coolant on corro ion. <strong>in</strong>clud<strong>in</strong>g<br />
<strong>the</strong> <strong>in</strong>vestigation of an adapted on-l<strong>in</strong>e<br />
Digi-Galv probe as a predictive tool.<br />
TECHINIOLOGY FOCUS<br />
'Normal Pr,obability 'Plot ot <strong>the</strong>Standardizedl Effacts<br />
(Response' 's Tim to' Alpha .. QI.10)<br />
• Identify and implement preventive practices<br />
to reduce <strong>in</strong>-proces corrosion.<br />
p<strong>in</strong>g. shot peen<strong>in</strong>g and <strong>in</strong>spection. Three<br />
(Cu plati:ng,carburiz<strong>in</strong>g. tripp<strong>in</strong>g). lap-<br />
Approacb. Scope, and Methodology gear parts (spur.helical, and planetary p<strong>in</strong>-<br />
This project was conducted <strong>in</strong> two ph as- lion) were selected from two separate gear<br />
IF""-~----------------'"'I,A: A Condition<br />
B: BAlloy<br />
C: C HT Conditio"<br />
0: D M<strong>in</strong>ute<br />
E E COnCentl'8\lon,<br />
F F Temperature<br />
G G Coolant Type<br />
es: Phase [ was to identify root causes of <strong>in</strong>- manufacturers as aresult of <strong>the</strong> process<br />
Sewage AI/lhorit)'. He is work<strong>in</strong>g on a $200 mil·<br />
process eorrosion by conduct<strong>in</strong>g a compre- mapp<strong>in</strong>g described above. These parts prohensive<br />
study. us<strong>in</strong>g manufactur<strong>in</strong>g process vided !he basi for detailed evaluations of eng<strong>in</strong>eer al <strong>the</strong> liT R~learch huri/wle (lrml)<br />
lion plant expansion project. He was a enior<br />
from 1999-2001.<br />
bench mark<strong>in</strong>g. at two gear production <strong>the</strong> signil'i.cant manufactur<strong>in</strong>g steps that<br />
facilities. The Phase ~ ludy was augment- were likely to <strong>in</strong>itiale <strong>in</strong>-process corrosion. Jim Reeves<br />
ed by controlled hlbomtory eX-PeriIllents. [II addition, parts selected were made cut is manager of proce s eng<strong>in</strong>eer<strong>in</strong>g QI Hont!ywell<br />
The desired end product of Phase I was ta of common base materials mat are widely Eng<strong>in</strong>e, Systems and Services' <strong>Gear</strong><br />
understand <strong>the</strong> sources .10:[ corrosion an ' used <strong>in</strong> <strong>the</strong> aerospace <strong>in</strong>dustry te manufac- Mamljacluri'lg Center of Excellence j'l Phoenix.<br />
! AZ He lias worked for HOl1eywell s<strong>in</strong>ce /980.<br />
gears dur<strong>in</strong>g <strong>the</strong> manufactur<strong>in</strong>g proces and ~ (Ore gears. The materials selected were wilen he starred as a grilldillg operator, Reeves<br />
10 identify solution to m<strong>in</strong>imize <strong>the</strong> corm- : 9310 (AMS6260, AMS6265) and Pyre- is a ctmifitd six sigma black.belt.<br />
sian problem. Phase D was to implement i wear X-53 (AMS6308) steels.<br />
<strong>the</strong> identified solutions to a restricted area l When <strong>the</strong> part selection and verifica- ~~ic~:~::~r for lhl! manufactur<strong>in</strong>g<br />
of <strong>the</strong> maaufacnmng floor to test <strong>the</strong>m <strong>in</strong> a !'",' of me manufactur<strong>in</strong>g steps were com- nologydivision of .lrrRl . .He holds a doctorare<br />
production environment. pleted.<strong>the</strong> FMEA was used to evaluate <strong>the</strong> <strong>in</strong> engif!eer<strong>in</strong>g'from Michigan' Stale Ulliversity.<br />
Phase [ <strong>in</strong>volved def<strong>in</strong><strong>in</strong>g <strong>the</strong> bound- process <strong>in</strong>puts. The F1vfEAs,allowed <strong>the</strong> His work <strong>in</strong>cludes projects for INFAC, flIt!<br />
aries of <strong>the</strong> gear mak<strong>in</strong>g process, develop-I. teamto prioritize processillputs that could <strong>in</strong>strumented factoryfor gears.<br />
<strong>in</strong>g detailedprocess Imps that describe all contribute to COIro ion <strong>in</strong>i~iation. Proces D'aony IMahan<br />
2<br />
01<br />
-11<br />
"EG<br />
of me steps required to produce <strong>the</strong> gears, I" connol charts and <strong>the</strong> f1vfEA were used to worked at lite U.S. .Army .Aviatioll GIld Missile<br />
verify<strong>in</strong>g <strong>the</strong> acmal <strong>in</strong>puts at each process identify and rank: <strong>the</strong> suspect <strong>in</strong>puts lobe Command ill Reds/one Arsenal, AL. as a supertep,<br />
and perfomt<strong>in</strong>g !he fmure mode and I tested. visor 0/ manufactur<strong>in</strong>g Scit!11C1! and tt!Chnolog),.<br />
01<br />
Standardized<br />
Figur:t 2 Normal ProbabililJ Pl{)t;<br />
effects analysis (FMEA) to assess priority<br />
of <strong>the</strong> process parameters. After <strong>the</strong><br />
process conditions that could potentially<br />
be contribut<strong>in</strong>g to corrosion <strong>in</strong>itiation were<br />
identilied and prioritized <strong>the</strong> design of<br />
experiments were planned and performed,<br />
For <strong>the</strong> proce s mapp<strong>in</strong>g. <strong>the</strong> boundary<br />
of <strong>the</strong> rudy was established from raw<br />
material handl<strong>in</strong>g through fmal <strong>in</strong>spection<br />
of <strong>the</strong> part. Typical eianutacturiag process<br />
step for gears <strong>in</strong>cluded turn<strong>in</strong>g, cutnng,<br />
hobb<strong>in</strong>g. deburr<strong>in</strong>g.<br />
gr<strong>in</strong>d<strong>in</strong>g •.heat treat<strong>in</strong>g<br />
Effect<br />
SooT. Nguvenl<br />
is a system control eng<strong>in</strong>eer<br />
at Upper Occoquan<br />
Itch.<br />
Iil'Ww.powBrlransmlssiM.com" ...",w.r/e.Jrtecftnology.com· OEAR lECHINOLOGY • JULY/AUGUST <strong>2002</strong> 31'
. -<br />
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Sf<br />
8E<br />
~c-<br />
CG --<br />
CE<br />
Of<br />
TECHNOLOGY IFOCUS,<br />
Normal Probability Plot of <strong>the</strong> Standardized Effects<br />
(Response is Time to .Alpha = 0.10,. Only 30 Largest 'Eflieets Shownl<br />
o 2 4<br />
Figure 3-Pal'eto<br />
A CQ"d~i.n<br />
.1<br />
-A-'<br />
_ ..<br />
of Effects.<br />
Interaction<br />
6 12<br />
Plot ~Data Means) for Time to I;nitiation<br />
-1 1 ·1 , -1 r -1 1 ·1 I -1<br />
B Allcy -I 9'<br />
• 1<br />
,1111-1<br />
Figure 4-1llteractioll<br />
.~ "'"<br />
:e<br />
.E<br />
B<br />
~<br />
Figure 3-Ma<strong>in</strong><br />
Plot..<br />
Effects Plot.<br />
C HT Condo ·1<br />
•I<br />
1!!!·'1<br />
, 0 M<strong>in</strong>utes Ex I.<br />
.··1 " : _-<br />
IIIE Concentration<br />
Ma<strong>in</strong> iEff,eets Plot ([lata Means) for<br />
lime to Initiation<br />
.A: .ACondition<br />
B:BAlloy<br />
C : C HI Condition<br />
D: 0 M<strong>in</strong>ute<br />
E : E Concentration<br />
F : Flemperatllre<br />
G: G Coolant Type<br />
~_;JI<br />
~<br />
1500<br />
1000<br />
500<br />
1500<br />
38 JULY/AUGUST <strong>2002</strong>' GEAR TECHNOLOGY' www.geartechnoJogy.com· www.powertransmJss on.com<br />
~<br />
~ ~<br />
--<br />
.---1<br />
FTemperitllre<br />
1<br />
.........---.<br />
~<br />
,<br />
Acreen<strong>in</strong>g analy is was performed by<br />
'olti'ng <strong>the</strong> hours 10 <strong>in</strong>itiation <strong>in</strong> ascend<strong>in</strong>g<br />
order and evaluat<strong>in</strong>g tile experiment<br />
matrix for any pattern. The visual pattern<br />
shown <strong>in</strong> Figure I that appeared 10 be . igniflcam<br />
i : coelam type. coolant condjtion,<br />
and an <strong>in</strong>teraction between eoolaru<br />
concentration<br />
and coolant type. A taJislical<br />
aaalysis was next performed, The normal<br />
probability plot and <strong>the</strong> Pareto of<br />
effects shown <strong>in</strong> Figure 2 and Figure 3<br />
respectively, identified '<strong>the</strong> same facto as<br />
be<strong>in</strong>g significant. Figure 4, <strong>the</strong> <strong>in</strong>teraction<br />
plot, 'howed <strong>the</strong> coolant type by coolant<br />
concentration as <strong>the</strong> mo t significant<br />
<strong>in</strong>teraction <strong>in</strong> <strong>the</strong> model. The ma<strong>in</strong> effects<br />
pI. t. Figure 5, <strong>in</strong>dicated that coolant concentration<br />
and coolant type had <strong>the</strong> greatest<br />
effect. An analysis of variance<br />
(ANOVA) confirmed <strong>the</strong> re uljs reported<br />
above as statistical I.)' ignificam, Based on<br />
tile data. virg<strong>in</strong> and low concentration<br />
coolants are predicted to <strong>in</strong>itiate corrosion<br />
more quickly than reclaimed and higher<br />
coacentration<br />
coolants.<br />
Heal treat condition alsoaffected <strong>the</strong><br />
<strong>in</strong>itiation<br />
of corm. ion <strong>in</strong> that rugh carbon<br />
(carburizeCl) urface were more resi tanl<br />
110 <strong>in</strong>itiation as compared '10 core (unearburized)<br />
wfaces. It was also, yn<strong>the</strong>sized<br />
from. <strong>the</strong> data set '!hat u ed/reclaimed<br />
cool ants offered better corrosion resi tance<br />
IhI: !'I.I_~11OI\I<br />
WW... pOWllr,,"n,mluUM.com •.......... g .. "·.chnology.com • GEAR TECHNOLOGY" JUl Y/AUGUST <strong>2002</strong> 39
TECHNOLOGY<br />
FOCUS<br />
Factors<br />
pH<br />
Copper ozJgaL<br />
Exposure time Im<strong>in</strong>.l<br />
I i<br />
I<br />
, .,'<br />
.l I I<br />
., .,<br />
I ., .,<br />
-i I \<br />
Attack<br />
·1 2<br />
., 2<br />
I, Lllvel " "+• Level" ••<br />
10.3<br />
9.9<br />
90<br />
8.6<br />
'6.3<br />
45<br />
F.igure6-Alkalille Strip Experiment<br />
Matrix.<br />
Figu.re 7-PCI- W<strong>in</strong> Probe System..<br />
Figure 8-PCl·<br />
Will Sweep Output.<br />
application method. Based on this resun,.<br />
<strong>the</strong> manufactur<strong>in</strong>g specification was modified<br />
to only require a quick immersion <strong>in</strong><br />
lieu of a four-m<strong>in</strong>ute soak. The practice<br />
was quickly implemented <strong>in</strong> Phase U.<br />
Chemical Attack<br />
Dur<strong>in</strong>g <strong>the</strong> project, a large quantity of<br />
gears were exhibit<strong>in</strong>g a pitted condition at<br />
<strong>the</strong> mach<strong>in</strong><strong>in</strong>g operations <strong>in</strong> various areas.<br />
After metallurgical exam<strong>in</strong>ation, it was<br />
determ<strong>in</strong>ed that <strong>the</strong> pits were a result of<br />
chemical attack/corrosion. S<strong>in</strong>ce <strong>the</strong><br />
machiae cutt<strong>in</strong>g fluids, clean<strong>in</strong>g and<br />
preservation factors had been previously<br />
tested <strong>in</strong> Phase I, <strong>the</strong>y were quickly dismissed<br />
as <strong>the</strong> root cause. This allowed <strong>the</strong><br />
team to focus <strong>the</strong> <strong>in</strong>vestigation <strong>in</strong> <strong>the</strong> plat<strong>in</strong>g<br />
facility. The key factors were identified<br />
through a thought process mapp<strong>in</strong>g exercise.<br />
Possible <strong>in</strong>itiators of <strong>the</strong> attack were<br />
alkal<strong>in</strong>e pH,expos1IIfe time, and <strong>the</strong> ounces<br />
of copper <strong>in</strong> <strong>the</strong> alkal<strong>in</strong>e strip solution. An<br />
experiment was designed. to test <strong>the</strong>se factors<br />
an 9310 steel specimens as shown <strong>in</strong><br />
Figure 6..Analysis of <strong>the</strong> experiment. identified<br />
pH as <strong>the</strong> factor with <strong>the</strong> highest significance.<br />
Data also <strong>in</strong>dicated when <strong>the</strong> pH<br />
level was greater than W, chemical attack<br />
did not occur.<br />
For phase II implementation, <strong>the</strong> team<br />
<strong>in</strong>stalled a controller on <strong>the</strong> alkal<strong>in</strong>e strip<br />
tanks to ma<strong>in</strong>ta<strong>in</strong> <strong>the</strong> tank pH levels above<br />
lO.3, by automatically add<strong>in</strong>g anhydrous<br />
ammonia when <strong>the</strong> pH level dropped<br />
below 10.3, It was noted !hat dur<strong>in</strong>g <strong>the</strong><br />
anhydrous ammonia addition, an. exo<strong>the</strong>rmic<br />
reaction occurred,heat<strong>in</strong>g <strong>the</strong> solution<br />
to temperatures above HJO"F.The problem<br />
identified with <strong>the</strong> elevated temperature<br />
was that when <strong>the</strong> alkal<strong>in</strong>e stripp<strong>in</strong>g SOJIItionreached<br />
temperatures above 77°P, it<br />
became corrosive to carbon steels. The<br />
team <strong>in</strong>stalled a chill<strong>in</strong>g unit <strong>in</strong> <strong>the</strong> stripp<strong>in</strong>g<br />
tanks to stabilize <strong>the</strong> solution temperature<br />
at 60"E After <strong>in</strong>stall<strong>in</strong>g <strong>the</strong> chiller and<br />
ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g stable pH levels at 10.3-10,7,<br />
no chemical attack on an entire lot of gears<br />
has occurred due to pH imbalance as a root<br />
cause.<br />
Residual Coolant<br />
Early <strong>in</strong>. <strong>the</strong> project, it was determ<strong>in</strong>ed<br />
by extensive laboratory test<strong>in</strong>g that waterbased<br />
mach<strong>in</strong><strong>in</strong>g coolant was an effective<br />
corrosion. <strong>in</strong>hibitor. Low carbon alloy gears<br />
coated with a film of <strong>in</strong>-process coolant did<br />
not corrode after two months <strong>in</strong> <strong>the</strong> high<br />
heat and humidity test chamber.<br />
The results of this test<strong>in</strong>g were:<br />
• Used coolant is not a corrosion enabler,<br />
• The coolant solution's ability to form a<br />
protective film barrier on <strong>the</strong> surface of <strong>the</strong><br />
part determ<strong>in</strong>ed its ability to <strong>in</strong>hibit corrosion.<br />
Whe<strong>the</strong>r this film came (rom virg<strong>in</strong><br />
or <strong>in</strong>-process coolant was irrelevant.<br />
.•If a film was not left on <strong>the</strong> part by <strong>the</strong><br />
coolant after <strong>the</strong> mach<strong>in</strong><strong>in</strong>g operation and<br />
it was not properly treated with a preservative<br />
oil, <strong>the</strong>n corrosion was enabled. Such<br />
corrosion resulted <strong>in</strong> <strong>in</strong>creased manufactur<strong>in</strong>g<br />
costs andlead times.<br />
·401 JULY/AUGUST <strong>2002</strong>' GEAR TECHNOLOGY· www.geartechno/Qgy.com' www.powertransm;ss on. com<br />
• A corrosion-protective film could be<br />
formed after process<strong>in</strong>g through ei<strong>the</strong>r <strong>the</strong><br />
coolam or preservative solution typically<br />
applied dur<strong>in</strong>g <strong>the</strong> msnufacnmng process.<br />
Test results <strong>in</strong>dicated that residua]<br />
coolant would leave a short-term COITOsian<br />
<strong>in</strong>hibit<strong>in</strong>g film an <strong>the</strong> gears similar<br />
to <strong>the</strong> ones result<strong>in</strong>g from immersion ill<br />
an oil bath. This residual film could<br />
reduce <strong>the</strong> <strong>in</strong>cidence of corrosion even if<br />
<strong>the</strong> preservative oil was not applied. If<br />
<strong>the</strong> proper flu.id attributes could be measured<br />
and ma<strong>in</strong>ta<strong>in</strong>ed, not only would<br />
costly corrosion <strong>in</strong>itiation be greatly<br />
reduced, but <strong>the</strong> corrosion prevention<br />
steps (preservative baths) could also be<br />
decreased or elim<strong>in</strong>ated.<br />
On-l<strong>in</strong>e PCI-W<strong>in</strong> Probe<br />
A significant barrier to. rely<strong>in</strong>g on residual<br />
coolant as rut effective short-term COfrosion<br />
:<strong>in</strong>hilbitor is determ<strong>in</strong><strong>in</strong>g if <strong>the</strong><br />
coolant has !he proper attributes. Standard<br />
corrosion test<strong>in</strong>g takes too long to give<br />
usable <strong>in</strong><strong>format</strong>ion ill an Oil-go<strong>in</strong>g production<br />
environment. For example, this test<strong>in</strong>g<br />
procedure would take approximately 48<br />
hours to complete at added cost for coolant<br />
analysis. The team's goal was to f<strong>in</strong>d a tool<br />
to provide real time sump-site test<strong>in</strong>g to'<br />
predict <strong>the</strong> coolant's corrosion <strong>in</strong>hibit<strong>in</strong>g<br />
properties.<br />
After fur<strong>the</strong>r research.<br />
<strong>the</strong> team decided<br />
on !he use of an adapted Digi-Galv prob<strong>in</strong>g<br />
system, PCl-W<strong>in</strong> Probe, similar <strong>in</strong> operat<strong>in</strong>g<br />
pr<strong>in</strong>ciple to <strong>the</strong> one: u ed <strong>in</strong> <strong>the</strong> oil<br />
pipel<strong>in</strong>e monitor<strong>in</strong>g <strong>in</strong>dustry. The probe<br />
has<strong>the</strong> potential to provide quick <strong>in</strong>dicationsof<br />
a coolant's corrosion-<strong>in</strong>hibit<strong>in</strong>g<br />
capabidties.<br />
The PCl-Wm Probe system shown <strong>in</strong><br />
Figure 7, consists of a small test. cell (specimen<br />
hous<strong>in</strong>g and electrode), a digitally<br />
controlled dual range precision <strong>in</strong>strument<br />
unit, and a standard Pentium desktop PC<br />
with <strong>the</strong> AMPLICON PC30AT crud and<br />
associated software <strong>in</strong>stalled. In addition,<br />
three accessories are added: a glass sleeve<br />
sample vessel, a constant temperature<br />
water bath with tub<strong>in</strong>g to allow flow<br />
through <strong>the</strong> glass sleeve, and a pump to<br />
provide circulation of <strong>the</strong> sample. The<br />
accessories create a test<strong>in</strong>g environment<br />
that simulates <strong>the</strong> actual conditions under
which '!.he coolantsperform <strong>in</strong> <strong>the</strong> metalwork<strong>in</strong>g<br />
mach<strong>in</strong>es,<br />
The PO-W<strong>in</strong> Probe effectively measures<br />
<strong>the</strong> electrical resi lance between <strong>the</strong><br />
probe and metal specimen while both are<br />
submerged LI1 <strong>the</strong> coolant be<strong>in</strong>g analyzed.<br />
The resi tance represents <strong>the</strong> film formed<br />
by <strong>the</strong> coolant on <strong>the</strong> specimen. The higher<br />
<strong>the</strong> resistance, <strong>the</strong> more complete <strong>the</strong> coverage<br />
and !.he thicker !.he film. This resistance<br />
is measured and graphed by <strong>the</strong> PCI-<br />
W<strong>in</strong> Probe system, <strong>in</strong> <strong>the</strong> form of a<br />
"sweep" shown <strong>in</strong> Figure 8. 1be sweep<br />
consists of two parts, cathodic and anodic.<br />
The anodic portion (above <strong>the</strong> X-axis, or<br />
po itive voltage values) of <strong>the</strong> sweep <strong>in</strong>dicates<br />
<strong>the</strong> rust preventative (RP) packages<br />
of <strong>the</strong> fluid. The longer <strong>the</strong> curve rema<strong>in</strong>s<br />
<strong>in</strong> <strong>the</strong> vertical. upsw<strong>in</strong>g. <strong>the</strong> better RP packages<br />
<strong>in</strong> <strong>the</strong> fluid. Also, !.he fur<strong>the</strong>r ,to <strong>the</strong> left<br />
thai. !he <strong>in</strong>flection po<strong>in</strong>t occurs, <strong>the</strong> better<br />
RP' <strong>in</strong> <strong>the</strong> fluid. In general, an <strong>in</strong>flection<br />
po<strong>in</strong>t. at 01" to' <strong>the</strong> left of 10 !lA <strong>in</strong>dicates<br />
fluid that is considered to be a good<br />
<strong>in</strong>hibitor of rust As. <strong>the</strong> RP package weakens,<br />
<strong>the</strong> sweep tends to trail off toward <strong>the</strong><br />
right If no <strong>in</strong>flection po<strong>in</strong>t oecursat all,<br />
and <strong>the</strong> sweep cont<strong>in</strong>ues flatly toward <strong>the</strong><br />
right, it demonstrates that <strong>the</strong> fluid's RP<br />
properties have depleted and are provid<strong>in</strong>g<br />
very little, if any, rust protecl.ion.<br />
Us<strong>in</strong>g two common gear materials, laboratory<br />
test<strong>in</strong>g of five' water-based metalwork<strong>in</strong>g<br />
coolants and validation test<strong>in</strong>g of<br />
two coolants were completed. Sample test<strong>in</strong>g<br />
was done at Honeywell Eng<strong>in</strong>es and<br />
Systems. Ten mach<strong>in</strong>es were strategically<br />
selected to provide a broad range of<br />
mach<strong>in</strong><strong>in</strong>g processes and coolant conditions,<br />
l<strong>in</strong> total, 10 weeks oftests were run<br />
with !.he two conditions for 9310 alloy and<br />
three weeks of tests were run with <strong>the</strong> two<br />
conditions for Pyrowear X-53 alloy. The<br />
purpose ofihe test was to validate previous<br />
results and to directly oorrelate<strong>the</strong> data<br />
ga<strong>the</strong>red <strong>in</strong> <strong>the</strong> sweep (location, <strong>in</strong>itiation<br />
of <strong>in</strong>hibition) to !he daily concentration,<br />
pH, bacteria, and total dissolved solids<br />
(TDS) levels.<br />
The results obta<strong>in</strong>ed <strong>in</strong> <strong>the</strong> lab did agree<br />
with <strong>the</strong> Phase I results. In compar<strong>in</strong>g <strong>the</strong><br />
Pel-W<strong>in</strong> sweeps, it was evident that <strong>the</strong><br />
a<br />
TECH:NIOLOGY<br />
FOCUS<br />
betteroorrosion <strong>in</strong>hibitor than <strong>the</strong><br />
ChemTool Cf-757 syn<strong>the</strong>tic coolant, Not<br />
only did <strong>the</strong> coolant type make a difference<br />
<strong>in</strong> sweep location and shape, <strong>the</strong> type of<br />
alloy was also, a factor; For <strong>the</strong> Pyrowear X-<br />
53 alloy. <strong>the</strong> sweeps were shifted far to <strong>the</strong><br />
rigilt In <strong>the</strong> DOE phase of this project,<br />
AMI Systems Co ..announce:s tllat II. 'Is now a<br />
manufactur<strong>in</strong>g: source of spiral gear rough<strong>in</strong>g<br />
and f<strong>in</strong>ish<strong>in</strong>g cutlers and bodies.<br />
We also can rnanutaeture new spiral<br />
cuner bodies In diameters 01 S" through 1'2"<br />
at present.<br />
AMI can also supply rough<strong>in</strong>giand f<strong>in</strong>ish<strong>in</strong>g'<br />
cunsrs for moslS'-12' dlameler bodies.<br />
Whelher it's service or manllla.clllr<strong>in</strong>g, consider<br />
us as an alternative source for cutters<br />
and bodies.<br />
You'll be <strong>in</strong> for a pleasant surprise.<br />
metal coupons made of PyrowearX-53 and<br />
9 1 310 were placed <strong>in</strong> a humidity chamber<br />
and monitored for <strong>the</strong> <strong>in</strong>itiation of corteion,<br />
The Pyrowear X-53 coupons exhibited<br />
corrosion <strong>in</strong>itiation before <strong>the</strong> 9310,<br />
which correlated to <strong>the</strong> 1PC1-W<strong>in</strong>f<strong>in</strong>d<strong>in</strong>gs.<br />
Additionally, it was dear that rout<strong>in</strong>e concentration,<br />
pH, bacteria, and IDS test<strong>in</strong>g<br />
did not predict pertonoance of rust <strong>in</strong>hibit<strong>in</strong>g<br />
packages <strong>in</strong> coolants.<br />
The PCI-W<strong>in</strong> Probe system did show<br />
an ability to differentiate between <strong>the</strong> two<br />
fluids' corrosion <strong>in</strong>hibit<strong>in</strong>g pertormance,<br />
However, <strong>in</strong> its current<br />
form, <strong>the</strong> PCI- W<strong>in</strong><br />
system is best suited for a laboratory<br />
NEW! Ho'b and Sbal/er c-uner Res'llarpen<strong>in</strong>g,<br />
is Inow IIvailabh" at A/W Sifs1ems, Companv Royal Oak, Michigan 48067<br />
Tel: (248) 544·3852- Fax: :(248) 544·3922<br />
FUCHS PT-97 soluble oil coolant was a SEE US AT IIIMTS <strong>2002</strong>-80'0'TH 8-71'30<br />
www.powerrransm/ss/on.com ....... w.gearI8chn0/ogy.com • GEAR TECHNOLOGY" JULY/AUGUST <strong>2002</strong> 41<br />
envi-
TECHNOLOGY<br />
FOCUS<br />
ronment, Additionally, because of several<br />
equipment stability issues, <strong>the</strong> team decided<br />
that it was not robust and precise enough<br />
to implement for production floor use.<br />
More test<strong>in</strong>g and evaluation were required.<br />
As fur<strong>the</strong>r research and development is<br />
conducted, it is expected that this technology<br />
could become a useful predictive tool<br />
for both lab and production environments<br />
Conclusions<br />
When corrosion occurs dur<strong>in</strong>g <strong>the</strong> manufactur<strong>in</strong>g<br />
of gears, production costs associated<br />
with scrapp<strong>in</strong>g or rework escalate,<br />
and product delivery delays are likely due<br />
to <strong>the</strong> disruption of work now with<strong>in</strong> <strong>the</strong><br />
product l<strong>in</strong>es. Based on this project, <strong>the</strong> key<br />
parameters and preventative practices to<br />
m<strong>in</strong>imize corrosion dur<strong>in</strong>g <strong>the</strong> manufactur<strong>in</strong>g<br />
of aerospace gears have been identified<br />
as follows:<br />
• Coolant condition, type, and coolant concentration<br />
are <strong>the</strong> major factors effect<strong>in</strong>g<br />
<strong>the</strong> <strong>in</strong>itiation of <strong>in</strong>-process corrosion ..In this<br />
project, low concentration and virg<strong>in</strong><br />
coolants will <strong>in</strong>itiate <strong>in</strong>-process corrosion<br />
more rapidly than higher concentration<br />
and<br />
reclaimed coolants,<br />
• With respect to <strong>in</strong>hibit<strong>in</strong>g <strong>in</strong>-process corrosion,<br />
soluble oil coolant performed<br />
than syn<strong>the</strong>tic coolant.<br />
• Carburized<br />
better<br />
surfaces are more resistant to<br />
corrosion <strong>in</strong>itiation than uncarburized surfaces,<br />
• Corrosion protection results are similar,<br />
regardless of <strong>the</strong> preservative oil application<br />
method, quick immersion or several<br />
m<strong>in</strong>utes' soak,<br />
• The alkal<strong>in</strong>e strip step <strong>in</strong> <strong>the</strong> plat<strong>in</strong>g<br />
process is a major source of chemical<br />
attack. Ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g pH levels between<br />
10.3-10.7 and fluid temperature at 6O"F<br />
maximum <strong>in</strong> <strong>the</strong> alkal<strong>in</strong>e strip tank will<br />
m<strong>in</strong>imize <strong>the</strong> potential for chemical attack<br />
on gears,<br />
• Residual coolant can be an effective<br />
short-term corrosion <strong>in</strong>hibitor, <strong>the</strong>reby<br />
elim<strong>in</strong>at<strong>in</strong>g <strong>the</strong> tirne-consum<strong>in</strong>g and costly<br />
oil preservative steps dur<strong>in</strong>g <strong>the</strong> manufactur<strong>in</strong>g<br />
of gears. The key to implement<strong>in</strong>g<br />
this practice is to have a reliable method of<br />
monitor<strong>in</strong>g<br />
<strong>the</strong> coolant conditions,<br />
• The PCI- W<strong>in</strong> Probe system has <strong>the</strong><br />
potential of characteriz<strong>in</strong>g <strong>the</strong> corrosion<br />
<strong>in</strong>hibitor characteristics of a coolant.<br />
Recommendations for Future Work<br />
Additional work On develop<strong>in</strong>g <strong>the</strong> PO-<br />
Will Probe system as an onl<strong>in</strong>e coolant<br />
tester is recommended, Once <strong>the</strong> coolant's<br />
corrosion <strong>in</strong>hibitor property is ascerta<strong>in</strong>ed<br />
through onl<strong>in</strong>e test<strong>in</strong>g,<strong>the</strong> possibility exists<br />
to elim<strong>in</strong>ate <strong>the</strong> preservative oil. altoge<strong>the</strong>r<br />
and rely solely on <strong>the</strong> residual coolant as an<br />
effective short-term corrosion <strong>in</strong>hibitor,<br />
Suggestions for improvements to <strong>the</strong> PC]-<br />
W<strong>in</strong> Probe system <strong>in</strong>clude <strong>the</strong> follow<strong>in</strong>g:<br />
• The calomel electrode should be manufactured.<br />
to a tighter tolerance,<br />
• A calibration method must be developed<br />
for <strong>the</strong> PCI-WilrProbe system to improve,<br />
accuracy.<br />
• The probe assembly should be repackaged<br />
to be mor-e rugged and portable.<br />
Acknowledgment.<br />
This project was conducted by<br />
Honeywell Eng<strong>in</strong>es & Systems and adm<strong>in</strong>istered<br />
by lIT Research Institute {IlTRfj<br />
through <strong>the</strong> INFAC (Instrumented Factory<br />
for<strong>Gear</strong>s)<br />
Program, which is funded by <strong>the</strong><br />
U.S, Army Aviation and Missile Command<br />
(AMCOM). Process mapp<strong>in</strong>g was done<br />
both at Honeywell Eng<strong>in</strong>es & Systems and<br />
Bell Helicopter Textron Inc, Humidity<br />
chamber and coolant test<strong>in</strong>g were conducted<br />
at Honeywell. Castrol Industrial developed<br />
<strong>the</strong> methodology for <strong>the</strong> PCl- Willl<br />
Probe test<strong>in</strong>g of <strong>the</strong> coolants, The authors<br />
would like to thank <strong>the</strong> staffs of AMCOM,<br />
lIT Research Institute, Honeywell. Eng<strong>in</strong>es<br />
& Systems, Bell Helicopter Textron Inc,<br />
and Castrol Industrial for <strong>the</strong>ir help and<br />
support all this project 0<br />
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t- iPRODUCTNEWS _<br />
Products for <strong>the</strong> <strong>Gear</strong> Industry<br />
INew Polvm.er for Brake Ac1uator<br />
From Victrex USA<br />
'TIlePeek polymer was chosen as <strong>the</strong><br />
material for <strong>the</strong> actuator unit of an electronically<br />
controlled park<strong>in</strong>g brake because<br />
it allowed TRW of Koblenz, Germany. to<br />
develop a high efficiency gear<strong>in</strong>g concept<br />
with a transmission ratio of .50:] with<strong>in</strong> a<br />
limited space.<br />
Accord<strong>in</strong>g to Victrex's press release.<br />
<strong>the</strong> polymer provided. lighter. quieter runn<strong>in</strong>g<br />
parts than could be achieved with<br />
metal.<br />
On this gear as embly, high torque was<br />
to be transmitted <strong>in</strong> a chemically aggressive<br />
environment with<strong>in</strong> a limited space. The<br />
subassembly sits 011 <strong>the</strong> caliper <strong>in</strong> <strong>the</strong> rim. a<br />
result of which was that <strong>the</strong> construction<br />
space available for <strong>the</strong> gear<strong>in</strong>g was only<br />
2.08" <strong>in</strong> diameter and 1.2" <strong>in</strong> height,<br />
Victrex USA is a manufacturer of high<br />
performance polyketones.<br />
For more <strong>in</strong><strong>format</strong>ion, contact Victrex ,<br />
USA Inc. of Greenville, SC, by telephone j<br />
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WWl1l.victreX.CGrlL j<br />
!<br />
New G:earml from Dow Com<strong>in</strong>g<br />
Molykote syn<strong>the</strong>tic gear o:ils from<br />
Dow Corn<strong>in</strong>g Corp. can las! three times<br />
longer than conventional :m<strong>in</strong>eral oils<br />
while reduc<strong>in</strong>g power consumption by as<br />
much as 17% <strong>in</strong> worm gearboxes, accord<strong>in</strong>g<br />
to Dow Com<strong>in</strong>g.<br />
In its pre release, <strong>the</strong> company said<br />
<strong>the</strong> oils' longer life is po sible due to proprietary<br />
anti-oxidant additives and a manufactur<strong>in</strong>g<br />
proce s that elim<strong>in</strong>ate impurities<br />
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The e gear oils are designed for use <strong>in</strong><br />
worm, helical, spur, bevel, hypoid, and<br />
rack and p<strong>in</strong>ion applications and meet<br />
most equipment OEM lubrication requirements.<br />
For more <strong>in</strong><strong>format</strong>ion, contact Dow<br />
Corn<strong>in</strong>g of Midland. MI. by telephone at<br />
(800) 637-5377 or on <strong>the</strong> Internet at<br />
www.molykote.com.<br />
Flaw iDe1.ec1orsfrom Agfa, NOT<br />
The USM 25 Serle of portable flaw<br />
detector from Agfa NDT weigh .3.5 lbs,<br />
and has a range of 0.020" <strong>in</strong> steel for<br />
optimum th<strong>in</strong>-range u e.<br />
Accord<strong>in</strong>g 10 <strong>the</strong> company's press<br />
release, curvature correction has been<br />
added to compensate<br />
for trigonometric<br />
flaw location calculations when perform<strong>in</strong>g<br />
angle beam <strong>in</strong>spection on pip<strong>in</strong>g and<br />
tubular goods. Two <strong>in</strong>dependent monitor<br />
gate, along with automatic A-Scan<br />
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Multiple-curve DAC with two<br />
curves above and below <strong>the</strong> orig<strong>in</strong>al<br />
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flaw siz<strong>in</strong>g capabilities. An alphanumeric<br />
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for 5,000 thickness read<strong>in</strong>gs and<br />
<strong>the</strong> ability to attach 500 A-Scans to<br />
thickness<br />
read<strong>in</strong>gs,<br />
For more <strong>in</strong><strong>format</strong>ion.<br />
contact Agfa<br />
NDT of Lewistown. PA. by telephone<br />
at (717) 242-0327 or bye-mail at<br />
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New <strong>Gear</strong> F,actory Software from<br />
IChr;isWatts IDesign<br />
Chris Walts Design is offer<strong>in</strong>g a new<br />
software system for AutoCAD 2000,<br />
20001, <strong>2002</strong> and MDT u ers, The software,<br />
called <strong>Gear</strong> Factory. <strong>in</strong>cludes a<br />
dialog box. that allows users to create<br />
standard or custom 3-D solid models, 2-<br />
D entities or 2-D isometric entities of<br />
standard <strong>in</strong>volute gears.<br />
Accord<strong>in</strong>g to <strong>the</strong> company's website.<br />
users can specify <strong>the</strong> pitch, pressure<br />
angle, number of teeth, width and <strong>in</strong>sertion<br />
po<strong>in</strong>t of gears. The soflware is available<br />
for $79.95 per unit,<br />
For more <strong>in</strong>forraation, contact Chris<br />
Watts Design of Ojai, CA, by telephone<br />
at (80S) 649-8038 or on <strong>the</strong> Internet at<br />
www.cwattsdesign.com.<br />
INew Slizesfor G,e.arheadl Serlies<br />
hom Thomson Industries<br />
Thomson Micron L.L.c. added 90<br />
and US mm sizes of planetary gearheads.<br />
Available <strong>in</strong> both <strong>in</strong>-l<strong>in</strong>e and right<br />
angle models, <strong>the</strong>se gearheads are suitable<br />
for applications like material handl<strong>in</strong>g.<br />
packag<strong>in</strong>g, coil w<strong>in</strong>d<strong>in</strong>g, pipe<br />
44 JULY/AUGUST <strong>2002</strong>' GEAR TECHNOLOGY· www.gurrechnofogy.com. www.powor/ransmission.com
Rev<br />
I<br />
II tion<br />
vol<br />
gma<br />
Fullv.IUB,tull ,ca;pacity<br />
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I'i fEI:18111N<br />
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ILearn how <strong>the</strong> Micro-top and Sigma Series systems<br />
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Website: hUpi/www.lecount ..com.(<strong>in</strong>cludes pn)dlJct specifications)<br />
46 JULY/AUGUST <strong>2002</strong> • GE.AA TECHNOLOGY' w.. w.gesrrechnc;logy.com •.. ww.powe'/fsnsm/ulon.com<br />
__ P,RODUC·T NEWS _<br />
bend<strong>in</strong>g, mach<strong>in</strong>e tools. overhead gantry<br />
systems and <strong>in</strong>jection meld<strong>in</strong>g mach<strong>in</strong>es.<br />
With a standard four ar ·m<strong>in</strong>ute backlash<br />
and crowned helical carburized steel<br />
gears that are hardened to HRC 60 m<strong>in</strong>imum<br />
and flank-f<strong>in</strong>] hed after heat treat<strong>in</strong>g,<br />
<strong>the</strong> gearhead are made to operate<br />
quietly. Accord<strong>in</strong>g 10 Them on' press<br />
release. <strong>the</strong> gearheads' strength and torsional.<br />
rigidity result from mach<strong>in</strong><strong>in</strong>g<br />
both <strong>the</strong> 'Output hous<strong>in</strong>g and <strong>the</strong> helical<br />
<strong>in</strong>ternal gear from a s<strong>in</strong>gle piece 'Of high<br />
trength steel.<br />
For more <strong>in</strong><strong>format</strong>ion, contact<br />
Thomson Industrie Inc. of Port<br />
Wash<strong>in</strong>gton, NY, by telephone al. (516)<br />
883-8000 or by fax at. (516) 883-9039.<br />
New Helica~ Shaft !Mount Reducer<br />
Emerson Power Transmission <strong>in</strong>troduced<br />
a newly redesigned Brown<strong>in</strong>g<br />
New Generation<br />
of CNC Gr<strong>in</strong>ders<br />
helical<br />
shaft mount reducer.<br />
The new haft mount l<strong>in</strong>e <strong>in</strong>corporate<br />
a <strong>in</strong>gjetapered bush<strong>in</strong>g mount<strong>in</strong>g<br />
system and a barrier steel system.<br />
The s<strong>in</strong>gle tapered bush<strong>in</strong>g mount<strong>in</strong>g<br />
system is reversible and allows <strong>the</strong> bush<strong>in</strong>g<br />
to mount from ei<strong>the</strong>r side. Wt <strong>in</strong>cludes<br />
a tapered stabilizer r<strong>in</strong>g that m<strong>in</strong>imizes<br />
wobble and resists frett<strong>in</strong>g corrosion.<br />
Accord<strong>in</strong>g to EPT's press release. this<br />
y tern reduces shaft b<strong>in</strong>d<strong>in</strong>g found <strong>in</strong><br />
two-bush<strong>in</strong>g systems and can replace<br />
any competitive s<strong>in</strong>gle- or double-bush<strong>in</strong>g<br />
shaft mounts.<br />
The barrier seal system comb<strong>in</strong>es a v-<br />
r<strong>in</strong>g face eal, grea e-fitled labyr<strong>in</strong>th and<br />
rotat<strong>in</strong>g outer flnger to provide triple<br />
protection aga<strong>in</strong>st contam<strong>in</strong>ation and oil<br />
seal. damage.<br />
For more <strong>in</strong><strong>format</strong>ion. contact<br />
Emerson Power Transmission of Jlbaca,<br />
NY. by telephone at (606) 564-2.084 'Or<br />
onl<strong>in</strong>e at www.emerson-ept.com.<br />
The Parker Majestic Division of Penn<br />
United Technology announced <strong>the</strong> development<br />
of a new generation of CNC<br />
cyl<strong>in</strong>drical. rotary and profile shift<br />
gr<strong>in</strong>ders.<br />
The Liberty Series are Siemens 810-<br />
powered mach<strong>in</strong>es with a 12" x 10" or a 14"
--- ------<br />
PR.DiDUCT INIEWSI<br />
_<br />
x 30" capacity, De igned to simplifylile<br />
management and programm<strong>in</strong>g. <strong>the</strong> series<br />
can be configured as an m. 00 or comb i-<br />
nationgr<strong>in</strong>der. Additionally, it features a 5<br />
hp 00 motor and [.5 hp ID motor.<br />
The Revolution Serie conta<strong>in</strong>s CNC<br />
rotary gr<strong>in</strong>ders with II 14" maximum<br />
diameter capacity chuck. These gr<strong>in</strong>ders<br />
can be configured with .3 vertical or horizontal<br />
gr<strong>in</strong>d<strong>in</strong>g sp<strong>in</strong>dle and are switchable<br />
from aile to <strong>the</strong> o<strong>the</strong>r, Grmders<br />
have <strong>the</strong> capacity to gr<strong>in</strong>d r<strong>in</strong>g and<br />
spacers flat with<strong>in</strong> 0,0000 1" and are<br />
menu driven.<br />
The Freedom Series of CNC profile<br />
urface gr<strong>in</strong>ders is comprised of 3-axls<br />
Siemens 810- and 840D-powered<br />
mach<strong>in</strong>e with an 8" x 18" table capacity<br />
and an optional C C over-<strong>the</strong>-wheel<br />
form dire er. These gr<strong>in</strong>ders can also be<br />
configured with a CNC rotat<strong>in</strong>g or<br />
<strong>in</strong>dex<strong>in</strong>g fixture,<br />
For more <strong>in</strong><strong>format</strong>ion, contact Penn<br />
United Technology of Saxonburg. PA. by<br />
telephone at (866) 572-7537 or on <strong>the</strong><br />
Internet at www.parkermajestic ..com.<br />
<strong>in</strong>g tower applications by adjust<strong>in</strong>glbe<br />
height ofjhe output Shaft. Also, <strong>the</strong> location<br />
of <strong>the</strong> change gears was designed .0 that<br />
spiral bevel gears with<strong>in</strong> <strong>the</strong> rna<strong>in</strong> hous<strong>in</strong>g<br />
do not have to be modified 10 cbange ratios,<br />
Numerous gear ratios call be achieved<br />
by us<strong>in</strong>g different sets of change gears<br />
extemalto <strong>the</strong> ma<strong>in</strong> hous<strong>in</strong>g. Therefore,<br />
<strong>the</strong> company says, <strong>the</strong> drive can be<br />
<strong>in</strong>stalled<br />
ill 24 hours with only <strong>the</strong> smaller<br />
change gears need<strong>in</strong>g<br />
when <strong>the</strong> unit is ordered.<br />
to be <strong>in</strong>stalled<br />
For more <strong>in</strong><strong>format</strong>ion. contact<br />
Philadelphia <strong>Gear</strong> Corp. of Nord town,<br />
PA, by telephone al (800) 766-51.20 or on<br />
<strong>the</strong> Internet at www.philagear.col1l.<br />
Ten Us Whit You Th<strong>in</strong>k ...<br />
V'lIit www.~c.lD<br />
• RIa. this col_<br />
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ReishauerRZ362,<br />
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xperienced<br />
New Universal'Cool<strong>in</strong>g<br />
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A new universal cool<strong>in</strong>g rower drive<br />
from Philadelphia <strong>Gear</strong> Corp. is deigned<br />
to replace cool<strong>in</strong>g tower drives<br />
and pare parts.<br />
Available <strong>in</strong> two sires. !he universal cool<strong>in</strong>g<br />
tower drive can be used <strong>in</strong>stead of o<strong>the</strong>r<br />
drive model • with m<strong>in</strong>imal modiJication. It<br />
conta<strong>in</strong>s spacer plates and change gears,<br />
Accord<strong>in</strong>g to <strong>the</strong> company's pre s<br />
release, base plate spaee adapters make <strong>the</strong><br />
drive modifiable to most o<strong>the</strong>r legacy cool-<br />
Call N'ow!<br />
Our experienced eng<strong>in</strong>eer<strong>in</strong>g<br />
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.FAIRFIELD<br />
GEARED' FOR EXCEHfNCE<br />
IFairfiel'd Manllfactl.ll1<strong>in</strong>g Company, I<strong>in</strong>c.<br />
Lafayette, IN 47903-7940 USA<br />
Telephone (765) 772·4000<br />
FAX (765) 772-4001<br />
\IIIWW.fairfleldmfg.com<br />
.--..--~ -<br />
IIfWW.powertransm/SSlon,com • www ..g.eartachnology.com • GEAR TECHNOLOGY' JULY/A.UGUST 2'002 47
~,.,.. - SEE US AT IMTS BOOTHI #18-'6781 ~ I<br />
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48 JULY/AUGUST <strong>2002</strong>" GEAR TECHNOLOGY' www.geartechnotogy.com· www.powertransmlsslon.com
- - -<br />
Ajax Magnethcrmic Corp.<br />
American MeLal Trt~'.at<strong>in</strong>g Co.<br />
Arro» <strong>Gear</strong> Co.<br />
AIW ysrems Co.<br />
Baril International Corp.<br />
Bourn & Koch Mach<strong>in</strong>e Tool Co.<br />
The Broach Masters loc.l<br />
Universal <strong>Gear</strong> Co.<br />
Chamfermatic Inc.<br />
Colonial Tool Group Inc.<br />
The D.C. Morrison Co.<br />
Dr. Kaiser (S.L. Munson)<br />
Dragon Precision<br />
(Greg Allen Co.)<br />
Dura-Bar<br />
Tool Co. LId.<br />
Fairfield Manufactur<strong>in</strong>g Co. Inc.<br />
F;is~ler' orp.<br />
<strong>Gear</strong> MOlions Inc.<br />
G~ar Tec~nology ~Center. .<br />
01 v. of MII~ubl ..hi International Corp.<br />
Gleason Corp.<br />
Glea!>on CUll<strong>in</strong>g Tooh Corp.<br />
The Gleason Work~<br />
rMTS <strong>2002</strong><br />
Index Teehnologie Inc.<br />
Insco Corp,<br />
I later tal" Tool Corp.<br />
rrw Heartland<br />
Kl<strong>in</strong>gelnberg-Oerlikon<br />
Koepfer America .l.L.c.<br />
Kreiter <strong>Gear</strong>teeh<br />
LeCoumlnc.<br />
Liebherr <strong>Gear</strong> Technolo y Co,<br />
LMT·Fette<br />
M&M Precision Systems Corp.<br />
\idy,e\l <strong>Gear</strong> & ioollnc.<br />
MidWe51 <strong>Gear</strong> Corp.<br />
Newage Te~L<strong>in</strong>g Instruments Inc.<br />
Niagara<br />
<strong>Gear</strong> Corp.<br />
PcIt} Technology Corp.<br />
po ....enrunsmission.com 1loI<br />
The Purdy Corp.<br />
Reishauer Corp.<br />
Russell. Holbrook & Henderson Inc.<br />
Sun-SU Inc.<br />
Star-S Inc. (Wesl Branch Indu tries)<br />
SU America Inc.<br />
United Tool Supply<br />
VOl Veri,,!.!<br />
AD'VE'RTISIER INDEX<br />
--- -<br />
USE RAPID! IREADERIRESPONSEto centaet any advertiser <strong>in</strong> this, issue<br />
www.geartechnology;com/rrr.htm<br />
Rapid Reader RespDnse: It's FAS,T! It's EASY! It's ONLY ONUNE!<br />
Pagel<br />
16,31<br />
50<br />
51<br />
4<br />
41<br />
46<br />
17<br />
43<br />
19<br />
10<br />
48<br />
33<br />
32<br />
5<br />
47<br />
15<br />
50<br />
13<br />
50<br />
1.50.51<br />
lFC<br />
14<br />
51<br />
16<br />
51<br />
17<br />
8<br />
51<br />
51<br />
46<br />
35<br />
6<br />
45<br />
34<br />
51<br />
42<br />
50,51<br />
IBC<br />
48<br />
39<br />
II<br />
4<br />
BC<br />
51<br />
3<br />
15<br />
J.t<br />
Pholl!<br />
(703) 684-02 II<br />
(800) 547-1527<br />
(;.! 16) 431-4:191<br />
(630) 969-7640<br />
(248) 544-3852<br />
(s·m 272-8128<br />
(815) 965-4013<br />
(530) 885·1939<br />
(815} 636-.5082.<br />
(5191.:!53-2461<br />
(888) 246-6]65<br />
(859) 581-7511<br />
(800) 775·1390<br />
(440) 331-0038<br />
(800) 2270.6455<br />
(815) 338-7800<br />
(765) 772-4000<br />
(414) 769-0072.<br />
(315) 488-0100<br />
(248) 669-6136<br />
(585) 473·1000<br />
(8151 877-8900<br />
(585) .1.73-1000<br />
(800) 3224687<br />
(703) 893-2900<br />
(440) 895-t627<br />
r978) 448-6368<br />
(216) 671-1077<br />
(320) 762·8782<br />
(734) 429-7225<br />
(1147) 93141111<br />
713) 237-9793<br />
(800) 642·6713<br />
( 02) 296-2200<br />
(734) 429-7225<br />
(734) 0129-2095<br />
(937) 859-827<br />
(586) i);l.·89~J<br />
(330) 425-W19<br />
(800) 806·3924<br />
(215) 526-2200<br />
(800) 447-2392<br />
(7161874·3131<br />
( oo) 738-2525<br />
(8-17) 437-6604<br />
(8OO)649-0000<br />
(847) 8 -3828<br />
(20 I) 796-5445<br />
(847) 649-1450<br />
(888) 73742.77<br />
1(989) 34 -2865<br />
(847) 649-1450<br />
(800) 755-0516<br />
(49) 2lI..fiJ8&·133<br />
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lech@agma.org<br />
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ajaxsales @ajaxmag.cQm<br />
mark(£!1 arncricanmetaltreatlngcem<br />
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people@barit.com<br />
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sales@broachmasters.com<br />
chamfe/%@aol.com<br />
bmfroal @"mn,i.nel<br />
rvbbj@jUl1u.com<br />
<strong>in</strong>fo@slmunson.com<br />
gallenco@msn.com<br />
sales@durll·bar.com<br />
sales fairficldmfg.com<br />
usu@fae"ler-ag.ch<br />
<strong>in</strong>fo@ mitsubi shigearcenter ..com<br />
dmelton iilgleason,com<br />
dmcllOn@glcason,com<br />
dmetlon@ leason.com<br />
gaJlenCQ ~com<br />
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klaus.s<strong>in</strong> ler@1 t.liebberr.eorn<br />
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kreiler@kreiler- eaneeh.eom<br />
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lmlfelte@llmlfe!tc.com<br />
<strong>in</strong>fQ@mmpreci:;iUl,.~Qm<br />
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ronh@mw ear.com<br />
<strong>in</strong>fo@newage<strong>in</strong> truments.com<br />
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--<br />
CLASSIFIEDS<br />
- -<br />
----<br />
WEBSJTES<br />
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IJTERATURE<br />
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CORPORATION<br />
('k~l.... t'III'lhl.' \\~'Jhl", 111l1'1~"'IIIPldh.·lbl\V<br />
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TO ADVERTISE IN THE<br />
CLASSIRED SECTION OF<br />
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CALL PAT FLAM<br />
AT (841) 431-6604 TODAYI<br />
Rates---..:L<strong>in</strong>e Classified: 1" m<strong>in</strong>imum, $325. Additional l<strong>in</strong>es $45 per l<strong>in</strong>e (8 l<strong>in</strong>es per <strong>in</strong>ch). Display Classified: 3" m<strong>in</strong>imum: lX-$735 .<br />
.JX-$68S per <strong>in</strong>sertion. 6X-$645 per <strong>in</strong>sertion ..Additional per <strong>in</strong>ch: lX-$2-5S. 3X-$23S per <strong>in</strong>sertion,6X-$225 per <strong>in</strong>sertion. Color<br />
~: Add $150 per <strong>in</strong>sertion for color. <strong>Gear</strong> Technology wiU set type toadvert:iser' 13)'001 or design a classified ad at no extra charge.<br />
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--- ----<br />
SERVICE<br />
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a<br />
me. ar. n~anufacturer • typically u e<br />
plastic, steel or o<strong>the</strong>r metals 1.0.<br />
make <strong>the</strong>ir gears. but Andrew<br />
Shotts made his fir 1. gears aut<br />
of sugar and chocolate.<br />
These materials are more familiar 10<br />
Shotts. A a pastry chef. he has worked<br />
<strong>in</strong> <strong>the</strong> kitchen. of <strong>the</strong> Russian Tea<br />
Room .. La Cote<br />
Ba que and <strong>the</strong> ocean<br />
l<strong>in</strong>er Queen Elizabeth 2. III 2001. he<br />
worked with twa colleagues to. create<br />
sugar and chocolate geaJ"s <strong>in</strong> that year's<br />
National Pastry Team Championship,<br />
Considered <strong>the</strong> premier event of <strong>the</strong><br />
pastry world, <strong>the</strong> annual pastry champion<br />
hip requires contestants to. create a<br />
chocolate showpiece, a sugar showpiece,<br />
cakes, plated desserts. frozen<br />
dessert and pelit fours urroundiag a<br />
<strong>the</strong>me. Intemational feam vie for a<br />
grand prize of 50,000.<br />
While rackjng <strong>the</strong>ir bra<strong>in</strong>s for 8.<br />
vision of how to best illustrate <strong>the</strong> 2001<br />
competition's Hollywood <strong>the</strong>me. Ihe<br />
chefs an Team Shotts were <strong>in</strong>spired by<br />
1930s actor Charlie Chapl<strong>in</strong> and decided<br />
to. design an entry to. honor his performance<br />
<strong>in</strong> Ihe movie Modem TImes.<br />
Noth<strong>in</strong>g symbolized <strong>the</strong> message of<br />
Modem Times better than a gear, says<br />
Shotts.<br />
"II had to be a gear because,<br />
dur<strong>in</strong>g<br />
(<strong>the</strong>) Depression, <strong>the</strong>re was so much<br />
more an emphasi on <strong>the</strong> mechanical,<br />
ra<strong>the</strong>r than On humans," he say .<br />
Shotts and hi colleague. Patrice<br />
Caillot and Remy Fi.<strong>in</strong>frock. constructed<br />
two. gears.<br />
One gear was <strong>the</strong>team's<br />
sugar howpiece, '<strong>the</strong> o<strong>the</strong>r was it.<br />
chocolate<br />
showpiece.<br />
"We were depict<strong>in</strong>g<br />
an old movie reel<br />
with tile sugar howplece," say Shotts.<br />
"II' <strong>the</strong> same ize film, 16 mm. that was<br />
1I<br />
ed when <strong>the</strong> movie was shot The white<br />
parts are upposed Ie be film wheels and<br />
<strong>the</strong> entire (annal<br />
of lhal. gear is representative<br />
of that old over-and-under<br />
of !he 1936 movie camera."<br />
<strong>format</strong><br />
The chocolate showpiece looks<br />
much like <strong>the</strong> ugar one, but. <strong>the</strong>re are<br />
some subtle differences between <strong>the</strong>m.<br />
At <strong>the</strong> bottom of <strong>the</strong> chocolate howpiece,<br />
for example. are fanlike cutout<br />
resembl<strong>in</strong>g a shutter. Both creations<br />
show gear curv<strong>in</strong>g on ei<strong>the</strong>r side to<br />
illustrate <strong>the</strong> mechanical nature of factory<br />
work dur<strong>in</strong>g<br />
<strong>the</strong> Depression.<br />
S<strong>in</strong>ce <strong>the</strong> creators were tra<strong>in</strong>ed <strong>in</strong><br />
cul<strong>in</strong>ary arts ra<strong>the</strong>r than <strong>in</strong> manufactur<strong>in</strong>g,<br />
<strong>the</strong>ir plann<strong>in</strong>g for <strong>the</strong> contest was<br />
extensive. They spent three months<br />
learn<strong>in</strong>g about mach<strong>in</strong>ery, design<strong>in</strong>g a<br />
template and mix<strong>in</strong>g <strong>the</strong> <strong>in</strong>gredients.<br />
Shotts. Fi<strong>in</strong>frock and Caillol began <strong>the</strong>ir<br />
creative process at <strong>the</strong> library, research<strong>in</strong>g<br />
gears <strong>in</strong> periodicals and trade journals.<br />
Once <strong>the</strong>y became comfortable with<br />
<strong>the</strong> construction of a gear. <strong>the</strong>y tried to<br />
devise <strong>the</strong> howpieces out of cardboard.<br />
They aved <strong>the</strong> cardboard template to a<br />
disk and sent it to an eng<strong>in</strong>eer <strong>in</strong><br />
Atlanta. who <strong>the</strong>n cut a mold to tbe<br />
exact specifications . Once <strong>the</strong>y had this<br />
mold 'back from <strong>the</strong> eng<strong>in</strong>eer,<br />
able 10. pour <strong>the</strong> chocolate<br />
bake.<br />
<strong>in</strong>to it<br />
<strong>the</strong>y were<br />
Each showpiece took eight hours to<br />
This year, Shotts and his partners are<br />
100 bu y with <strong>the</strong>ir day jobs to participate<br />
<strong>in</strong> <strong>the</strong> National Pastry Team<br />
Championship <strong>2002</strong> Contest. ShOHS<br />
works <strong>in</strong> ew York as a corporate pastry<br />
chef for Guiuard Chocolate CD. and<br />
launches a new l<strong>in</strong>e of seasonal! bonbons<br />
every<br />
three months,<br />
Caillot works as executive pastry<br />
chef at New York's St. Regis Hotel, pecializ<strong>in</strong>g<br />
<strong>in</strong> desserts, and Funfrock<br />
explores new desserts <strong>in</strong> his role as<br />
executive pastry chef at Cafe Boulud <strong>in</strong><br />
New York.<br />
Though <strong>the</strong>ir gears were probably<br />
better ta t<strong>in</strong>g than tho e made <strong>in</strong> factorie<br />
. <strong>the</strong> creators. opted to throw<br />
showpieces after<strong>the</strong> compctition.O<br />
out <strong>the</strong><br />
52. JUl Y/AUGUST <strong>2002</strong> • GEAR TECHNOLOGY' ,,,,,",w.gur,echflology. com' wWw.powlrlrlflsmlssloll.c·Qm<br />
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