Gear Grinding: Software

JUN
2018
GEAR GRINDING
• Optimize your Setup Time
• How to Check Your Nital
Etch ProcesS
SOFTWARE
• Systems for Battling
Gear Noise
www.geartechnology.com THE JOURNAL OF GEAR MANUFACTURING

SG 160
The first dry grinding machine for gears
The new Samputensili SG 160 SKY GRIND is based The innovative machine structure with two spindles
on a ground-breaking concept that totally eliminates the actuated by linear motors and the use of more channels
need for cutting oils during the grinding of gears. simultaneously ensure a chip-to-chip time of less than
2 seconds.
By means of a skive hobbing tool, the machine
removes 90% of the stock allowance with the first This revolutionary, compact and eco-friendly machine
pass. Subsequently a worm grinding wheel removes will let your production soar and improve your workers’
the remaining stock without causing problems of wellbeing.
overheating the workpiece, therefore resulting in a
completely dry process. Contact us today for more information!
This ensures a smaller machine footprint and

considerable savings in terms of auxiliary equipment,
materials and absorbed energy.
Phone: 847-649-1450
5200 Prairie Stone Pkwy. | Ste. 100 | Hoffman Estates | IL 60192
Visit Us at IMTS at North Hall 236909 and West Hall 432258
www.star-su.com
contents
JUN
®
2018
64
20
features
technical
20 Cutting Down on Setup Time
With increasingly smaller returns from 34 Selecting the Right Tooth Thickness
improving the speed of the actual gear This issue’s Ask the Expert column focuses on AGMA
grinding process, improving your setup time 2002-C16 and explains some of the nuances of the
standard.
has become a primary way to keep improving
efficiency. Here’s the latest on how you can do 36 Predicting Life on Through-Hardened Steel
that today. Rack-and-Pinion for Jacking Applications in the
Offshore Industry
26 Shake, Rattle and Roll Designing and sizing a rack-and-pinion system, per
AGMA and ISO gear calculation.
Software providers examine the dynamic
behavior of gear noise 44 Human Machine Interface (HMI) in Gear
Manufacturing
“Documentation is not a Substitute for an Intuitive
Interface.”
54 Standard Samples for Grinder Burn Etch

Testing
A different method to produce a sample that has a
very consistent amount of thermal damage.
Vol. 35, No. 4 GEAR TECHNOLOGY, The Journal of Gear Manufacturing (ISSN 0743-6858) is published monthly, except in February, April, October and December by Randall Publications LLC, 1840 Jarvis Avenue, Elk Grove
Village, IL 60007, (847) 437-6604. Cover price $7.00 U.S. Periodical postage paid at Arlington Heights, IL, and at additional mailing office (USPS No. 749-290). Randall Publications makes every effort to ensure that the processes
described in GEAR TECHNOLOGY conform to sound engineering practice. Neither the authors nor the publisher can be held responsible for injuries sustained while following the procedures described. Postmaster: Send
address changes to GEAR TECHNOLOGY, The Journal of Gear Manufacturing, 1840 Jarvis Avenue, Elk Grove Village, IL, 60007. Contents copyrighted ©2017 by RANDALL PUBLICATIONS LLC. No part of this publication may
be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission in writing from the publisher.
Contents of ads are subject to Publisher’s approval. Canadian Agreement No. 40038760.
2 GEAR TECHNOLOGY | June 2018

[www.geartechnology.com]
FIRST BUILT IN AMERICA IN 1896.
STILL BUILT BY AMERICANS IN 2018.
THE ORIGINAL FELLOWS GEAR SHAPER
www.bourn-koch.com
machinesales@bourn-koch.com
815-713-2367
contents
UNITE-A-MATIC™
SHOP HARDENED GEAR INSPECTION
WITH DATA COLLECTION ® Vol. 35, No. 4
TRUE DIMENSION GEAR INSPECTION™
departments
SOFTWARE HIGHLIGHTS
• Real Time Data Collection
• Gauge R&R Studies 06 GT Extras
• Gauge Database Management Gear Technology TV, Our Recap of the CTI
Transmission Symposium USA, and the GT Library:
You can only find them online.
REPORTING HIGHLIGHTS
• Analyze Inspection Data 09 Publisher’s Page
• Compare Data and Process Behavior Response Required.
• Customized Reporting
• Real-Time Reporting
10 Product News
New products and technologies from Erwin Junker,
Doosan, GWJ Technology and more
Available up to 15”
Larger custom 57 Subscriptions
builds available
Fill out the form to continue receiving Gear
Technology.
*NO ANNUAL SOFTWARE FEE 58 Industry News

AGMA/ABMA annual meeting highlights; news from
Gleason Corporation and Forest City Gear.
62 Advertiser Index
www.unite-a-matic.com Contact information for companies in this issue.
63 Calendar of Events
June 17–20: PowderMet 2018. San Antonio, TX
June 27–28: DRITEV. Bonn, Germany.
July 30–August 2: CAR Management Briefing
August 7–9: Ipsen
64 Addendum
Setting a Hundred-Year Standard.
NEW
Release
03/2018
KISSsoft Highlights
▪ Strength calculation of asymmetrical gears
▪ Displacement for bevel and hypoid gears
▪ Interface to GEMS® with data exchange JUN
2018
▪ Shaft editor with background drawing
GEAR GRINDING
▪ Calculation of conical compression springs • Optimize your Setup Time
• How to Check Your Nital
KISSsoft AG/Gleason Sales
▪ And many more ... Etch ProcesS
Brian P. Stringer SOFTWARE

Phone (585) 494-2470 Get your free trial version at • Systems for Battling
Gear Noise
info@KISSsoft.com www.KISSsoft.com
www.geartechnology.com THE JOURNAL OF GEAR MANUFACTURING

Cover image by David Ropinski

arTech_KISSsoft_Release2018_89x120_5mm.indd 1 26.04.2018 13:09:42

Liebherr Performance.
LC 280 α Gear Hobbing Machine

100 % Liebherr – Short delivery time
The LC 280 α gear hobbing machine is the perfect entry into gear cutting. It offers maximum flexibility
thanks to a diverse range of workpieces, well-known Liebherr quality, and low acquisition cost.
The machine with a new hob head and perfected chip removal is ideal for the supplier business,
especially because of the fast delivery time of approx. three months and high productivity.
Machining workpieces with max. 280 mm diameter and shafts with a length of up to 500 mm
Wet and dry machining possible
Dry machining with stainless steel housing available
Newly developed and optimized hob head for larger tools in diameter and length
Liebherr-Gear Technology, Inc.

Liebherr Automation Systems Co. 1465 Woodland Drive,
Saline, MI 48176–1259, USA
Phone: +1 (734) 429-7225
info.lgt@liebherr.com
GT extras
THE GEAR INDUSTRY’S INFORMATION SOURCE
www.geartechnology.com
Klingelnberg
The Höfler cylindrical gear grinding RANDALL PUBLICATIONS LLC
machine Speed Viper focuses on 1840 JARVIS AVENUE
high-productivity generating ELK GROVE VILLAGE, IL 60007
grinding in large-series manufac- (847) 437-6604
turing. Check out a video on its FAX: (847) 437-6618
features and capabilities here:
EDITORIAL
www.geartechnology.com/videos/ Publisher & Editor-in-Chief
Michael Goldstein
Cylindrical-Gear-Technology-/ publisher@geartechnology.com
Associate Publisher & Managing Editor
Randy Stott
Gear Technology TV wrs@geartechnology.com
Browse our webpage dedicated Senior Editor
Jack McGuinn
to original content prepared by jmcguinn@geartechnology.com
our editors, along with the help of Senior Editor
gear industry experts from around Matthew Jaster
the world. (www.geartechnology.com/tv/) mjaster@geartechnology.com
Associate Editor
Alex Cannella
alex@geartechnology.com
Editor’s Choice: Editorial Consultant
CTI Symposium 2018 Recap Paul R. Goldstein
Technical Editors
Read all about the presentations and William (Bill) Bradley, Robert Errichello,
discussions on the future of the auto- Octave Labath, P.E., John Lange, Joseph
motive industry as well as the latest Mihelick, Charles D. Schultz, P.E., Robert
E. Smith, Mike Tennutti, Frank Uherek
transmission and mobility technology
that took place at the CTI Symposium in DESIGN
Art Director
Novi, Michigan: David Ropinski
dropinski@geartechnology.com
www.powertransmission.com/blog/on-the-road-to-disruptive-technology/
ADVERTISING
Associate Publisher
& Advertising Sales Manager
GT Library: Heat Treating Dave Friedman
dave@geartechnology.com
Browse the GT Library for all the technical, feature, product and industry Materials Coordinator
news articles related to heat treating in the gear industry: Dorothy Fiandaca
dee@randallpublications.com
www.geartechnology.com/subjects/heat+treating/ e-Marketing Specialist
Matthew Stott
matthewstott@geartechnology.com
China Sales Agent
Eric Wu, Eastco Industry Co., Ltd.
Tel: (86)(21) 52305107
Fax: (86)(21) 52305106
Stay Connected Cell: (86) 13817160576
eric.wu@eastcotec.com
Join the Gear Technology
Facebook group at CIRCULATION
Circulation Manager
www.facebook.com/ Carol Tratar
groups/210890932629794/ subscribe@geartechnology.com
Circulation Coordinator
Barbara Novak
Follow us on Twitter bnovak@geartechnology.com
twitter.com/#!/Gear_Technology
RANDALL STAFF
President
Michael Goldstein
Connect with us on LinkedIn Accounting
www.linkedin.com/groups/Gear- Luann Harrold
Technology-Magazine-3893880
Subscribe Online
www.geartechnology.com/
subscribe.htm

PROUD DEALER OF
Burri Grinding Machines
Burri, the world market leader in upgrading Reishauer gear grinding
machines, now presents the all new BZ130 high-speed, double-spindle
grinder with a two-second chip-to-chip time and patented axle design,
(eliminating the need for an expensive turntable). Designed, engineered,
MACHINE TOOL BUILDERS and produced by Burri Werkzeugmaschinen in Germany; now available
with the world class service and support of Machine Tool Builders.
BZ130
Grinding speeds: 80m/sec
Chip to chip time: 2 sec
Double spindle patented design
Integrated loading system
designed for mass production
Compact Footprint (2.4 x 1.9m)
Visit MachineToolBuilders.com/Burri for details.

Contact us at 815.636.7502 or info@machinetoolbuilders.com
An engineer owned company built on complete customer

satisfaction. We can handle all of your machinery needs.
New machinery dealer of brands like Hera, Burri, Donner + Pfister,
and Diablo Furnaces
A world class MTB rebuild of your existing machine
MORE THAN 20 YEARS OF TOP QUALITY,
A custom MTB recontol of your existing machine
HIGHLY RELIABLE SOLUTIONS TO THE
We carry a limited inventory of rebuilt and recontrolled machinery
MACHINE TOOL INDUSTRY
On-site or off-site service and repair
[
HERA ]
The world's only threaded wheel
ZI20A
grinder for internal gears is a
technical triumph: the ZI20A.
Designed for quieter automobiles -
EV, HEV and conventional planetary
Internal Gear
transmissions , it allows customers to
accurately and quickly hard finish
internally toothed ring gears — at
Grinding Machine
significantly lower production costs.
You’ll want to shout about this

from the rooftops:
• Grinding speeds faster than

conventional honing
• Grinding-tool life extended for
considerable cost-per-workpiece
reductions
• 15,000 RPM for the main spindle,
6,000 RPM for the workpiece spindle
Among many MHI innovations present

in the ZI20A is a control technology for
highly accurate and efficient grinding,
which keeps costs considerably less
than other internal hard gear finishes.
Just one more example of how MHI
designs to the needs of the customer
and delivers groundbreaking solutions
with dependable results.
Contact Mitsubishi Heavy Industries

America today for specifications, and
learn more about how the MHI ZI20A
can quietly make a big impact on your
bottom line. Phone 248.669.6136 for
more information.
Machine Tool Division • Gear Technology Center

46992 Liberty Drive • Wixom, MI 48393
mitsubishigearcenter.com
BOOTH #N-237036
publisher's page
Response
Required
SAY `YES' TO GETTING THE BEST AND LATEST IN GEAR
INDUSTRY TECHNICAL INFORMATION & NEWS
Publisher & Editor-in-Chief

Michael Goldstein
There’s a subscription card attached to your mag-
azine this month. It’s glued to the front. You can’t
miss it. In addition, this is part of a much broader effort on our
Please fill it out. part to better serve the gear industry. Even though we already
If, by some chance, there’s no card attached to your maga- have, by far, the broadest reach among publications serving
zine, that doesn’t mean you’re off the hook. Maybe the card was our industry, we’re committed to expanding that even further.
removed by someone in the mailroom. Maybe it fell off in tran- We’re investing heavily in our circulation because we believe
sit. Maybe your colleague got tired of reading your copy and very strongly in this industry, and we want to serve as many
wanted to subscribe for himself. Whatever. Just turn to page 57. gear industry professionals as we possibly can. So far our efforts
There’s another copy there. Or just go to www.geartechnology. have paid off greatly. In the past month alone, we’ve grown
com/subscribe.htm if you’re reading this online. (Either way, our requested circulation by 10%, and we’re only just begin-
the whole process should take less than a minute.) ning. Mind you, we’re not just dumping in names to pad the
However you do it, we NEED your response. It doesn’t mat- list. We’re sending our magazine and e-mail products to more
ter if you’ve been receiving the magazine non-stop for 34 years people who want them. And that’s our goal.
(Thanks, by the way, if that’s the case) or if you’ve just signed You can help by filling out the form and sending it in.
up. It doesn’t matter if you’re an advertiser, industry bigwig
or close personal friend. If you want to keep receiving Gear
Technology, you MUST fill this out.
You see, we’re completely overhauling the way we handle
your information. That includes your name, job title, company
affiliation, mailing address, e-mail address and so on. We’re
doing everything we can to protect that information and to use
it responsibly. Michael Goldstein,
Many of you are aware that the European Union’s General Publisher & Editor-in-Chief
Data Protection Regulation (GDPR) went into effect last P.S. Send your subscription form to:
month. No doubt you’ve recently received a flurry of e-mails Gear Technology
asking you to re-opt-in to various lists, because publishers like 1840 Jarvis Ave.
us want to be able to continue serving you. Elk Grove Village, IL 60007 USA
But in many ways, what we’re doing goes way beyond the Or FAX it to 1-847-437-6618
GDPR. Yes, we want to protect your privacy. Yes, we want to Or SCAN it and e-mail it to publisher@geartechnology.com
use your e-mail address and personal information responsibly.
But more importantly, we want to provide you with information
that’s of value to you, and we want to provide it in the way that
makes most sense to you, not us. So we’re asking you to confirm
that you want the information, and we’re asking you to specify
how you want to receive it.
More importantly, we’re asking you to tell us a little bit about
yourself. It’s not because we’re nosy. It’s because the information
you provide helps us do our job better. Knowing who you are,
where you work and how you’re involved with the gear industry
helps us craft our magazine, newsletters and websites in a way
that appeals to the broadest spectrum of you.
June 2018 | GEAR TECHNOLOGY 9

product news
The Junker Group

EXTENDS GRINDING MACHINE RANGE WITH CORUNDUM LINE
The Junker Group has extended its
range of grinding machines: With its
new Zema corundum line, the company
is offering efficient solutions for con-
ventional grinding. Versatile, robust,
durable — Junker corundum grinding
machines fulfill the requirements of
series production for a wide range of dif-
ferent workpieces. The CNC grinding
machines grind elements such as flanges
and journals on crankshafts as well as
gear, turbocharger and cardan shafts or
spray nozzles with the utmost precision
and reliability. In total, the corundum
line comprises three models, each of
which has different focal points.
The Numerika is designed for the
series production of a wide variety of
different workpieces — up to a length of
3.50 meters in the biggest model. The These corundum grinding machines of automation. At the same time, they
cylindrical grinding machine Kargo are the ideal addition to the CBN offer the flexibility needed for grind-
takes ultra-heavy workpieces such as high-speed grinding machine series ing workpiece families: Several types of
shafts for generators or electric motors from Junker. They come with a robust a workpiece family can be stored in the
with weights of up to six tons easily in machine bed, hydrostatic guides and control system, allowing a quick change-
its stride. Rounding off the range are grinding spindles mounted on rolling over from one workpiece to another in
the Flexa corundum grinding machines, or hydrostatic bearings as standard. A production. To ensure a trouble-free
which are capable of solving up to three user-friendly control system comes with production sequence, the corundum
grinding assignments with the utmost all the necessary input masks for preci- grinding machines are also equipped
precision. Whether internal or external sion corundum grinding and excellent with automatic loading and unloading
grinding and even thread grinding: The surface quality. systems.
modular design of the robust Flexa series Designed for integration into pro- For more information:
makes it ideal for small and medium- duction lines, the corundum grinding Erwin Junker Machinery, Inc.
sized production runs. machines also come with a high level Phone: (847) 488-0406
www.junker-usa.com
Doosan Machine Tools America

INCREASES CAPABILITIES OF MULTI-TASKING TURNING CENTERS
If you want to turn out more completed parts on a single
machine with less operator time, Doosan has released the
PUMA SMX ST series. These super multi-tasking turn-
ing centers have axes everywhere. Both left and right
spindles are capable of high accuracy C-axis control and
the machine can perform various machining functions
like turning, milling and synchronized cutting all with a
single set-up.
The ST models come with all the advantages and fea-
tures of the SMX series. For starters, they have high-rigid-
ity machine construction, minimized thermal deforma-
tion via oil coolers, an accuracy control feature based on
multiple thermal compensation functions and a Y-axis
machining area that has been maximized through orthog-
onal design. Along with the largest machining space

BEVEL GEARS WORMS CAMSHAFTS
GEAR CUTTING TOOLS CYLINDRICAL WORM GEARS COMPRESSOR ROTORS
You make it, checks it.
Wenzel America Ltd. | 28700 Beck Rd. | Wixom, MI 48393 | Phone 248-295-8700 | www.wenzelamerica.com
product news
among the same-class machines, they lower turret with 12 tool stations allows 80 tool ATC. Then they added a lower
come standard with Doosan’s famous operators to be even more productive 12 station turret that can offer turning or
ergonomic features that enhance on a single mill turn CNC machine. A milling capability while still utilizing the
operator convenience and efficient static turret is standard, and turret for upper milling head to truly multi task.
maintenance. driven tools is optional, but this lower For more information:
The ST versions include the addition turret isn’t just for tools. Operators can Doosan Machine Tools America
of a lower turret turning/milling func- also drop in workholding equipment like Phone: (973) 618-2500
www.doosanmachinetools.com
tion to the existing left and right spindles steady rests, follow rests, tail stock center
and B-axis milling function. The tur- and two jaw vises.
ret comes on both of the new SMX ST
models: the 10" chuck version (PUMA
The SMX ST series comes with many
features. It starts with a full 5-axis multi- GWJ
SMX2600ST) and 12" chuck version
(PUMA SMX3100ST). The addition of a
tasking turning and milling machine
with a 12,000 rpm milling spindle and Technology
GmbH
INTRODUCES
NEW VERSION OF
SYSTEMMANAGER
SystemManager is an extension to the
web-based calculation software eAs-
sistant (web solution) and TBK.
SystemManager is a true software appli-
cation for complete systems of machine
elements, i.e., the software is a coupled
FE calculation of multishaft systems with
gears as non-linear coupling elements.
The new version provides an alternative
method of importing and automatically
meshing housings and planet carriers.
This offers an even better mesh quality
and allows a meshing of very complex
geometries, for example the geometries
of gearbox housings in automotive appli-
cations are known to be very complex.
The system calculation considers now
rotating 3D elastic parts for the calcula-
tion of eigenfrequencies (e.g., of planet
carriers) using modal reduction.
Coupling connections were added
in addition to the previous connection
types cylindrical gears, planetary gear
trains, bevel gears, worm gears and belts.
It easily allows to consider hydraulic or
electric connections between subsys-
tems. Many small extensions had been
added like splitting or merging shafts in
addition to copy, shift or mirror options.
All bearings types are now drawn with
separated inner and outer rings in 2D
and 3D views.The animations for 3D
mode shapes therefore allow a better
understanding of the movement in the
bearings. Graphics can be frozen inside
the program to allow comparisons and a
copy option using the system clipboard
was added for graphics for quicker trans-
fer into other documents. The default

POWER SKIVING
Efficiently geared. Completely machined.
The skiving center PITTLER PV315 is demands. The flexible use of technolo- internal and external gearings without
the preferred machining solution of a gy allows him to machine the part with changing the setup. At the end of the
manufacturer of marine transmissions. a maximum of two chucking processes, day, he saved the purchase expenditure
In search of an integrated solution with thus guaranteeing highest surface quali- of 5 single-process machines plus the
several machining processes like turning, ties. Thanks to the highly efficient gear- time-consuming re-tooling, transport
drilling, punching, gear cutting as well as ing technology Power Skiving, the trans- and storage cycles. Just recently, he
deburring the PITTLER PV315 met all his mission manufacturer can now produce invested in a second PITTLER PV315.
Turning inner diameter

Punching
Internal gear
cutting
Efficient production of internal and

Turning outer external gearings in one clamping setup.
diameter Drilling
External gear
cutting
Deburring
PITTLER PV315
 Power Skiving for inner and outer gearings
 Integrated tool magazine for complete machining
 Single clamping operation for highest precision
CONTACT US:
DVS Technology America Inc.
734-656-2080 sales.america@dvs-technology.com
www.pittler.de l www.dvs-technology.com
product news
format for reports is now PDF/A instead of standard PDF.

The software documentation is now available as context
sensitive help allowing faster access of information to
certain inputs. There are other new additions to the inte-
grated bearing calculation.
For more information:
GWJ Technology GmbH
Phone: +49 (0) 531-129 399 0
www.gwj.de
Emuge
INTRODUCES SELF-LOCK SYSTEM FOR THREADING TOOLS
Emuge Corp., a manufacturer of high Compared with standard threads, the forgetting the locking device. To gage
performance taps, drills, end mills and Emuge Self-Lock internal thread shows Self-Lock threads, Emuge recommends
other rotary tools, has announced its constant, maximum holding power using its two-piece gage system which
thread making tool quality is available under dynamic stress. Functions remain corresponds to the usual combination of
in a Self-Lock integrated locking system. in good operation even with repeated a go/ no-go gage.
Emuge Self-Lock threading tools offer a loosening and re-tightening of the Emuge Self-Lock Threading Tools work
high quality alternative in thread locking thread connection. This locking effect is with standard external threads (screws)
for vital safety applications in aerospace, caused by the ramp-shaped surface inte- with tolerance class “medium”. Internal
medical, communications, transporta- grated into the thread profile. threads can be produced with Emuge taps,
tion industries and more. Self-Lock technolog y results in cold forming taps or thread mills.
The Emuge thread locking feature is increased threading tool life for For more information:
integrated in the internal thread, and larger thread hole diameters and pro- Emuge Corp.
has a modified profile with a 30 degree vides larger tolerances for thread hole Phone: (800) 323-3013
www.emuge.com
ramp surface in the direction of stress diameters. Also, assembly is easy with
which provides the self-locking effect. In no assembly errors possible such as
an ideal screw connection for high-stress
situations, where there is a standard
external thread in an Emuge Self-Lock
internal thread, the internal thread yields
a self-locking screw connection that can
be used repeatedly.
“The special profile of the Self-Lock
thread allows an even distribution of
stress over the entire thread length and
therefore eliminates slippage,” said Mark
Hatch, product director at Emuge Corp.
“We are pleased to offer such a safety
critical threading solution which results
in no stripping of threads and is cost-
effective because no additional compo-
nents are necessary.”

Design
Smarter
Next-generation GEMS®
provides advanced gear
design and analysis tools to
optimize the entire bevel gear
manufacturing process. With
the new KISSsoft® Design
Interface, GEMS now offers
software tools to improve
the design and performance
of single gears, complete
gearboxes and drive train
systems.
www.gleason.com/design
N-237000
© Gleason Corporation. All rights reserved.
product news
Mahr
OFFERS OPTIMAR 100 WITH IMAGE PROCESSING
Mahr Inc. recently expanded its Optimar The upgrade kit incorporates a USB makes it possible to create and store test
100, a proven solution for testing dial 3.0 camera for fast image processing, certificates.
and digital indicators, test indicators and and stable daylight-independent LED The easy operation of the Optimar
dial comparators, with image process- illumination along with secure digital 100 with image processing speeds up
ing for the automated testing of mea- identification and reading of digits. The and facilitates the monitoring of the
suring equipment. A new upgrade kit QMSOFT software controls the measur- indicators under test. With the auto-rec-
now makes working with the measuring ing device, evaluates the camera image ognition of the vision system, more test
instrument safer and faster: a camera of the scale or number display of the items and data points can be recorded
automatically records the indicated val- test object, compares the values with the faster than with conventional manual
ues of the test indicators and forwards high accuracy internal reference scale methods. Since this is a completely auto-
them to a software for processing. The and automatically completes the process mated inspection system, the operator
automated procedure saves time and of calibrating the product under test. can be more productive in other opera-
replaces the exhausting and error- The software also tions while the Optimar 100 automati-
prone reading by the operator. cally completes the calibra-
The hardware and software tion process. This makes
add-on package provides a cost- indicator inspection much
efficient way to equip existing more economical.
measuring stations with Optimar For more information:
100 for automated testing. The Mahr Inc.
measuring system, including Phone: (401) 784-3100
www.mahr.com
image processing, is also available
as a complete package under the
name “Precimar Optimar 100 BV.”
All
All The
the Gear Cutting Tools You Will Ever Need are
Are Right Here
DTR is one of the world’s largest producers.
DTR. Your best choice for high quality gear cutting tools.
DTR is a world class supplier of the finest high performance long-life gear
manufacturing tools, for small and large gear cutting applications.
Established in 1976, we are one of the world’s largest producers of cutting
tools, shipping to over 20 countries.
DTR offers a full line of gear cutting tools including:
• Hobs • Chamfering and Deburring Tools
• Carbide Hobs • Broaches
• Shaper Cutters • Master Gears
• Milling Cutters
We can produce virtually any tool you need for auto, aerospace, wind,
mining, construction and other industrial gears.
Every tool is precision-made utilizing high speed steel, premium powder

metal or carbide and the latest in coatings, to achieve superior cutting and
long life. DTR uses top of the line equipment including Reischauer CNC
grinders and Klingelnberg CNC sharpeners and inspection equipment.
Learn more about our outstanding quality tools at www.dtrtool.com.

Call us at 847-375-8892 for your local sales representative or
Email alex@dtrtool.com for a quotation.
BOOTH #N-237017
DTR has sales territories available. Call for more information.

U.S. Office Location (Chicago) Email Headquarters
inquiries to: alex@dtrtool.com. 85, Namdong-daero 370beon-gil, Namdong-gu, Incheon, Korea, 21635
(formerly Dragon Precision Tools) 1865 Hicks Road, Suite A, Rolling Meadows, IL 60008
PHONE: +82.32.814.1540
WWW.DTRTOOL.COM PHONE: 847-375-8892 Fax: 224-220-1311 FAX: +82.32.814.5381

SMALLEST FOOTPRINT.
ergonomic access.
KAPP NILES KNe3P

gear profile grinding
Efficient and easy to use machine concept

with intuitive KNgrind software and HMI touch
screen, and prompt delivery time.
Best price performance and accuracy with well-known KAPP NILES quality.
KAPP Technologies
2870 Wilderness Place Boulder, CO 80301
kapp-niles.com info@kapp-niles.com (303) 447-1130
product news
Kitagawa NorthTech
ANNOUNCES SUITE OF AUTOMOTIVE WORKHOLDING
SOLUTIONS
Kitagawa NorthTech, Inc., recently NorthTech advanced chucks and custom
announced their suite of automotive fixtures that have been engineered, mod-
industry workholding solutions, which ified and/or customized to solve part
bundles together advanced and cus- specific machining for a myriad of auto-
tom engineered workholding products motive industry applications, includ-
ideally suited for automotive industry ing: camshafts, valves, cylinder pumps
machining applications. The advanced and heads, differential cases, brackets,
workholding series are Kitagawa clutches, covers, holders, gears, hubs,
pinions, pulleys, rotors, rollers, pistons,

Booth no.: 237058 chassis components and more.
The suite of automotive industry
SPIRAL BEVEL GEAR CUTTING MACHINE advanced/engineered chucks and work-
holding for automotive applications from
HIGH PRECISION, GOOD RELIABILITY, GREAT VALUE Kitagawa NorthTech includes:
• DL200 — Dual locking chuck with
increased gripping options and easy
jaw forming ideal for high volume
automotive machining applications.
• PWc and PWTc — 2 or 3 Jaw Power
wing chucks with powerful gripping
for irregular work pieces and tapered
parts. Provides secure gripping for
casting and forging applications.
• PU Type Pull Lock Chucks (PU, PUB
and PUE) — Draw down chucks for
high precision processing available
with open center types. High radial
gripping forces and strong pullback
action allows for stable cutting under
heavy load conditions.
CNC Spiral Bevel Gear Cutting Machine • FG Finger Chucks — for high speed
turning of 3 jaw wheel chucks for
Siemens 840D Controller, utilizing five (5) synchronized axes automotive and motorcycle alumi-
num wheels and 6 jaw chucks for OTR
LUREN designed easy to use, Microsoft Windows© based software
trucking applications.
Precision cutting to 100 mm O.D., with maximum Module of M3 • Collet Chucks — Short series collet
Cup type milling cutter with HSK tool holder & 4,000 RPM Spindle chucks, long series collet chucks, quick
Easy adjustment of contact pattern by point, click & drag change collets chucks and pull back
Also Available：LUREN’S LVG-100 Spiral Bevel Gear Grinding Machine collet chucks.
• Custom Fixtures — Weldment or
Casted base custom fixtures for a vari-
Our Gear Cutting Tools Hobs Shaper Cutters Master Gears
ety of horizontal and vertical machin-
For over 20 years of manufacturing, Luren ing applications.
has been offering a wide variety of custom
and standard gear cutting tools using the For much information:
highest quality materials and accuracy to Kitagawa NorthTech
ensure your longest possible tool life. Phone: (847) 310-8787
www.kitagawa.com
Corporate Headquarters North American Headquarters
Luren Precision Co., Ltd. Luren Precision Chicago Co., Ltd.
No.1-1, Li-Hsin 1st Road, 707 Remington Road, Suite 1,
Hsinchu City, Taiwan, 30078 Schaumburg, IL 60173, U.S.A.
Phone : +886-3-578-6767 Phone : 1-847-882-1388
Email : sales@luren.com.tw Email : Gerald_kuo@lurenusa.com
Website : www.luren.com.tw Website : lurenusa.com

The Complete Technical Solution for
Today’s Gear Grinding Challenges
JOIN US AT IMTS 2018 | BOOTH N-237042

to learn more about how Norton Xtrimium wheels master all of these
challenges for worm grinding, profile grinding and bevel grinding
http://nortonsga.us/xtrimiumgt
feature
Cutting Down on Setup Time

With increasingly smaller returns from improving the speed of
the actual gear grinding process, improving your setup time has
become a primary way to keep improving efficiency. Here’s the
latest on how you can do that today.
Alex Cannella, Associate Editor
With machining time itself hav-

ing gotten shorter and shorter
over the years — to the point
where it’s starting to see dimin-
ishing returns — savvy manu-
facturers looking for ways to
improve efficiency have turned
towards setup as one of the
most important steps of the
manufacturing process to shave
time off of.
Everyone approaches the task of
reducing setup time differently. Bill
Miller, vice president of sales and service
at Kapp Technologies, splits his com-
pany’s solutions between mass produc-
tion lines and batch manufacturing job
You can speed up setup time with new solutions that
shops. It’s obvious why job shops that reduce or virtually eliminate the need for tools during setup.
frequently switch between small batch
production runs would benefit from
improved setup time. Dr. Rolf Schalaster, reducing workplace errors, as they can primary way machine manufacturers are
manager of the competence center for be one of the greatest sources of lost pro- accomplishing just that is by simplifying
bevel gear grinding at Klingelnberg, ductivity. Time spent fixing a mistake is the design to reduce the number of tools
predicts that for small batch job shops, time lost not machining. required to set up a machine.
setup can even take up to 50 percent of a Different companies have taken a few “Sometimes, you need a whole tool-
manufacturer’s time. But Miller believes different strategies to accomplish this. box with different tools to setup the
it’s also an equally important topic for Some make the setup process simpler machine,” Türich said. “Our solution
mass production companies, even if they and provide instructions on how to set now requires just one simple tool, which
only set up a machine once or twice a up the machine, while others cut out the makes it much faster and easier.”
day. Even if you’re only grinding the chance for user error entirely through The solution Türich is referring to is
same workpiece repeatedly, grinding automation. Gleason’s Genesis GX threaded wheel
tools wear down and need to be swapped Suffice to say that people have come grinding machine series, a prime exam-
out. Workpieces still need to be periodi- up with a lot of inventive ways to reduce ple of the idea. Every screw you need to
cally tested for accuracy. These processes setup time over the years, and we’re interact with to complete setup has been
take time, and they can be reduced with going to highlight as many of them as standardized so that the machine can
the proper tools. possible. While some of these processes be completely setup from start to finish
According to Dr. Antoine Türich, are well-known and have been around with a single Allen wrench. According to
director of product management for for a while, they’re still constantly evolv- Türich, a central focus with the GX was
hard finishing solutions at Gleason, ing and are joined by other newer or less to make sure the machine was as fast and
there are four broad categories in which orthodox ideas. easy to set up as possible, requiring only
setup time can be reduced: the mechani- 10 minutes of setup time to change out
cal work of physically exchanging tools, Reduce the Need for Tools the grinding wheel, dressing tool, work-
workholding, and so on; teaching and One common way we can hasten the holding and gripper inserts before you’re
setting up a particular job before begin- setup process is to simplify it. After all, ready to get machining.
ning the actual manufacturing; inspect- the more straightforward something is Gleason can still do one better than
ing finished workpieces; and applying to setup, the fewer steps and less exper- that, though. According to Uwe Gaiser,
the eventual necessary corrections. tise required, and by extension, the director of product management of bevel
There’s also a great deal of focus on easier and faster the work will be. One gear solutions at Gleason, the process

can be as simple as just hitting a button
or flipping a switch. Just hit a switch to
release and swap out the workholding in
a process that takes “just a few seconds”
instead of dozens of minutes tightening
screws. Combine that with a hydraulic,
spring-loaded chucking system, and cut-
ters can be rapidly swapped out with ease.
“We have the same accuracy, but
instead of taking 10 minutes, you can do
this in 30 seconds depending on the size
of the cutter,” Gaiser said.
According to Miller, reducing the need
for tools can be particularly useful for More and more setup processes are becoming entirely automated, both
saving time and reducing expertise required to operate the machine.
mass manufacturing because it reduces
the need for specialized expertise. In
Miller’s experience, many larger high- processes ranging from changing out the are avoided.”
volume manufacturers can have their clamping device to verifying the run- Klingelnberg has developed a number
processes grind to a halt whenever a out are fully automated, reducing the of ways to help machine operators and
machine needs to be adjusted as some- amount of time skilled workers have to reduce errors with automation. This can
one runs to fetch an expert. That might spend working on a specific machine. manifest in small quality of life upgrades
sound like a mundane and barely note- Kapp’s advances are only one part of to existing processes such as how grind-
worthy issue, but when workpieces can a larger trend towards automation, the ing machines won’t start a grinding pro-
be ground out in seconds or minutes, latest advances of which are doing their cess if the wheel hasn’t been reprofiled
taking 10-20 minutes to hunt someone part to help combat the skill gap and after loading profile corrections have
down, get them over to the machine and reduce setup time as much as possible. been finished, or include bigger, stand-
solve the problem can put you behind. “In a global view, today’s machine alone solutions such as a smart tooling
Kapp’s KX-100/260 Dynamic machines operators are not necessarily experts system.
give high-volume manufacturers a boost on what they have to do like in former The tooling system is based around
by requiring zero hand tools or wrenches days with manually operated mechanical data matrix codes, which each fixture
to set up, meaning no expertise required. machines,” Schalaster said. “We believe tool in the system comes with. Scan the
Just put the tool on the flange and the that setting up obviously has to be as fast code and the fixture’s geometry gets
machine handles the rest. as possible. But in addition, it also has loaded directly into the machine with-
to be as safe as possible since mistakes out any need for input from the techni-
Automate! can quickly lead to time- and money- cian. Klingelnberg is also working so
Of course, options like the KX Dynamic consuming damages. Therefore, we try that in the future, a machine will auto-
series that just lets you plug a tool in to make the system smarter so that the matically know the geometry of both
and go couldn’t exist if the entire pro- single setup steps are easier, faster and new and used wheels immediately after
cess wasn’t automated to run itself. Many potential sources of error by the operator tool changes, reducing the time required
to program the machine before it gets to
machining.
The tooling system is also cur-
rently being implemented to work with
Klingelnberg machines’ automatic fast
profiling program, which minimizes
dressing time by automatically deter-
mining any necessary reductions of a
grinding wheel’s length and which areas
need to be dressed based on a list of four
to six parameters input by a technician.
According to Schalaster, Klingelnberg
would like to shave that time down even
further by implementing the smart tool-
ing system so that technicians won’t even
need to input the tool’s parameters, and
can instead just scan the tool and go.
K lingelnb erg’s to oling f ixtures
Gleason's Genesis GX series has multiple new innovations
designed to cut down on setup time and simplify the process. themselves have also seen a few

feature CUTTING DOWN ON SETUP TIME
modifications. Most notably, the fixtures calls a “one piece oil ring,” which is switch from generating grinding to
can be mounted entirely outside the designed for reducing the time required internal profile-grinding in less than 30
machine, meaning that the tools for the to set up oil pipes and nozzles for your minutes.
next job on the machine can be prepped coolant. The idea is for each nozzle to How does Liebherr accomplish this?
while another job is already running. be mounted on a single ring that can For one, they make sure the process is
Once it’s time for the next job, it only be quickly exchanged during setup. simple and easy. The machines’ internal
takes a handful of unscrewed bolts and a Instead of taking time adjusting your grinding arms can be mounted directly
few quick steps and the next tool’s ready nozzles for a new job while the machine onto the external grinding heads. Like
to go. The way Klingelnberg handles its is forced to stand idle, you can just with some earlier machines we’ve high-
fixtures is just one example of a com- swap out pre-adjusted sets of nozzles on lighted, no hand tools are required
pany-wide focus on another way you can each ring and go. to change out parts like inserts or the
cut down on setup time. Namely... Customers have a few options on how clamping fixture. Dressing tools are
they want to take advantage of the oil easy to switch out thanks to a hydraulic
Do More Outside the Machine rings. Mass manufacturers that only have expanding arbor. A machine mounted
While other companies focus on applica- a machine work on a few different parts jib-crane automatically mounts the
tion-driven solutions or individual steps can have multiple oil rings that they can internal grinding arms and changes
of the process, Klingelnberg has a taken slot in and out as each one is needed. For over grinding wheels. And then there’s
a unique approach to improving setup batch manufacturers working on many Liebherr’s LHGeartec software, which
time. Schalaster categorizes each element small projects, however, Klingelnberg allows the engineer to load any nec-
of the setup process as either external also offers a tool trolley that allows you essary programs for a given project
setup, which can be done outside the to pre-set an oil ring for the next job either at the machine or from an exter-
machine while it’s working on a previ- while the previous one is still running nal server and can lead the technician
ous job, or internal setup, which requires that can then be slotted in when it’s time through the setup process with its HMI.
the machine to stop. It’s not much of for the next workpiece. Samputensili’s SG 160 Sky Grind simi-
a surprise that many of Klingelnberg’s larly utilizes both hobbing tools and a
efforts focus on reducing internal setup Get Multitool Machines grinding wheel in a single machine. The
as much as possible, and they’ve opted Shifting as many steps as possible to be hobbing tool quickly removes most of a
to do so by shifting as much of that labor done outside a machine isn’t the only workpiece’s stock allowance in one pass,
into external setup processes as possible. way you can physically cut down on then a second pass with the grinding
“A decisive issue is to shift as many your setup time. You can always get a wheel finishes the job. In addition, it can
steps as possible from internal setup time machine that combines both external also change workpieces in the same lot
to external setup time,” Schalaster said. and internal grinding, such as Liebherr’s in under two seconds, further reducing
One such solution is what Schalaster LGG 180/280/400 M series, which can downtime by shaving off the margins
Closed loop systems are critical for shaving

time off the inspection part of your setup cycle.

Multitool machines like Liebherr's LGG M series can entirely
switch grinding methods in under 30 minutes.
of time between each individual work- few other solutions tackling setup time Gleason has developed software that
piece’s manufacture. that we’ve described, these quick change takes the machine through each of these
“The part changing time on the devices are run without requiring any steps on its own in 10 minutes, prepping
Samputensili SG 160 Sky Grind dry hand tools or specialized labor. They’ve it right up until it’s time to start machin-
grinding machine, and its wet grinding also begun to implement those same ing parts.
equivalent G-160, have a very quick part quick change components in grippers. “We have taken all these sub-cycles
change,” David Goodfellow, president of and created a complete new one we call
Star SU, said. “It is important to change Up Your Software the First Part Cycle,” Türich said. “And
the workpiece in the same lot in product Improving and iterating upon a what this First Part Cycle is doing is
in less than two seconds. This requires machine’s software is a pretty com- going through all the steps which are
high speed machine movements and mon method for reducing setup time. necessary after the mechanical work
design changes to realize this important Gleason’s Genesis GX series, for exam- until the first workpiece is being ground
cycle time reduction.” ple, also features software guidance on on the machine. So the machine does
In general, Star SU and its affiliated its screen that will take even unskilled everything automatically.”
companies have specialized in improv- operators through every step of the Similarly, you can opt to have your
ing setup time with servo and hydrau- setup process, telling them exactly what machine remember a job so you don’t
lic quick change actuating devices for they need to do. It reduces mistakes and have to teach it twice in the first place.
hobbing, grinding, shaping, shaving and allows less skilled operators to work Gleason offers software for CNC con-
CNC tool and cutter machines. Like a more quickly, both of which translate to trols that allows their machine to save
less downtime. and remember past settings.
Türich related a common occurrence “You can ask after an hour, after a day,
from when Gleason was showing off after a year,” Gaiser said. “If the customer
their Genesis GX line at open houses comes back to a specific ratio, it’s really
where, after demonstrating the feature, just the push of a button to activate that
visitors would volunteer to try and set data, activate that machine summary,
the machine up following its instructions and you have the same data like you
and, on the spot, were able to do so. used to have whenever you had the job
“They were really impressed with how the last time on the machine.”
easy it was and how fast they could learn The benefit of a repeatable setup is
it by using the software-guided instruc- self-evident: manufacturers can maintain
tions right on the machine,” Türich said. accuracy and, more importantly, repeat-
ability while greatly reducing setup time
Teach Your Machine by skipping any required calibration.
Software can also help improve your “If you don’t have a repeatable setup,
setup time by enabling your machine you will have to redevelop the job
to learn how to do new jobs faster than again…” Gaiser said. “The most prefer-
ever before. able way would be to be as close as pos-
According to Türich, one primary sible to the part geometry where you had
holdup in the setup process is the left off the cutting or grinding process
need to teach a machine new motions. whatever time ago.”
Meshing cycles, initial dressing, adjust-
ing coolant nozzles, calculating the tool Streamline Inspection
position; all of these steps take time Unlike with Gleason’s other solu-
and expertise to properly execute, and tions, Türich stressed that much of the

feature CUTTING DOWN ON SETUP TIME
inspection process is outside of the com- revolutionary today, but they’re

pany’s control. The process isn’t fully still an essential tool in reduc-
automated, so there will be variance ing your setup time. For example,
depending on how quickly a technician Klingelnberg’s Komet software suite
works, and there is no solution for two automatically calculates corrections
technicians that need to use the same to reduce flank form deviations and
inspection machine at the same time. remembers past corrections the
But looking at it from the opposite angle, grinding machine can load on its
streamlining those processes could also own. Klingelnberg has been work-
lead to improved efficiency. Organizing ing on expanding the software’s
your workflow so that everyone isn’t set- applications, most recently trans-
ting up their machines at the exact same lating it to cylindrical gear man-
time (and thus needing to inspect work- ufacturing, in addition to already
pieces) and would reduce the potential being used for bevel gear grinding.
for downtime where your technicians But despite the fact that Komet isn’t
would be sitting around waiting. even a new product and its only
One step that Gleason has imple- recent updates have been to expand Norton's Xtrimium grinding wheels can
mented is a closed-loop system in which its applications, the software suite grind and polish a gear without having
a Gleason inspection machine sends the still recently won an Industry 4.0 to be swapped out from the spindle.
inspection results directly back to the award, highlighting just how influential
production machine, removing the risk and important closed-loop systems still
of errors when interpreting results or are. between jobs to begin with? An option
inputting incorrect values. The produc- to consider is a grinding wheel that com-
tion machine compares the actual val- Use One Wheel to Grind and bines two different wheels into one.
ues with the programmed target values Polish For example, Norton | Saint-Gobain
and applies the necessary corrections Reducing the time it takes to set up a has been developing a new line of grind-
automatically. machine is all well and good, but what ing wheels called Norton Xtrimium that
Closed-loop systems aren’t necessarily if you didn’t have to change your setup help master the challenges in worm
Class I accuracy
Granite column PGM 165
Thermally compensated
High capacity table bearing
Linear drives
Motorized tailstock
Universal analysis software
Free unlimited software support
“Closed loop” corrections to production machines
Probe changer
Quick change of tooling
PGM 400
Made in USA
KAPP NILES Metrology | Dayton info@kapp-niles.com www.gearinspection.com (937) 660-8182

grinding, profile grinding and bevel it’s ready to swap in the instant you need as to the wide array of options available
grinding. The new line includes dual- it, but Miller recommends getting your to take advantage of, and you’ll find a
worm grinding wheels which combine supplier to do the dressing for you. Batch few that you can leverage.
a vitrified bond section to grind and a grinders in particular can improve their For more information:
fine-grit resin bond section to polish the efficiency by getting their supplier to Gleason
teeth of the gear, delivering an improved pre-dress their worms before they even (585) 473-1000
www.gleason.com
surface finish quality to reduce gear arrive on your doorstep.
noise in the final assembly. The dual- “Working together with the supplier, it Kapp Technologies
(303) 447-1130
worm wheels can be adapted to existing is possible to get that form much closer www.kapp-niles.com
machines. to the final form to reduce that time,” Klingelnberg America, Inc.
“Gear manufacturers are being asked Miller said. (734) 470-6278
to hold tighter tolerances, improve pro- The idea is to reduce dressing time www.klingelnberg.com
ductivity and improve surface finish,” during manufacturing by essentially hav- Liebherr Gear Technology, Inc.
Jennifer Thompson, application engi- ing your supplier do some of the work, (734) 429-7225
www.liebherr.com
neer at Norton | Saint-Gobain, said. “So such as pre-dressing, for you. According
Norton | Saint-Gobain
instead of having to swap out grind- to Miller, this can save up to 30-40 min- (508) 795-5000
ing wheels mid-job for different steps utes of setup time. www.nortonabrasives.com
of the process, manufacturers can use Star SU LLC
the Xtrimium dual-worm gear grinding Don’t Use Just One (847) 649-1450
wheels to rough and finish grind on one Often, many of these solutions are built www.star-su.com
spindle to achieve cost and time savings.” upon each other, work best alongside
each other, or even appear standard
Get Your Supplier Involved together in one machine, such as with
A major part of the setup process can Gleason’s Genesis GX and Kapp’s KX For Related Articles Search
be dressing a wheel before getting to Dynamic. Not every solution is going
the actual grinding. Manufacturers have to fit your specific needs, be they batch grinding
come up with a few ways of handling manufacturing, mass production, or at www.geartechnology.com
this situation, including dressing a sec- based on a specific grinding method, but
ond wheel while the first one grinds so hopefully this has given you a few ideas

feature
Shake, Rattle and Roll

Software Providers Examine the Dynamic
Behavior of Gear Noise
Matthew Jaster, Senior Editor
Some truth about gear noise: Meeting Gear Noise

Electric motors compared to Challenges Today
combustion engines are close Platten believes there are essentially
to inaudible. For both electric and four main challenges today when
hybrid vehicles the engine noise that is looking at gear noise:
covering the gear noise is gone, there- The challenge of reducing product
fore, in low-speeds when tires and wind development times and costs while
noise are low, the demands to the gears simultaneously meeting the demands
are much higher concerning noise. of improved noise and vibration
In pure electric cars, gear speeds quality.
are typically higher (10,000 rpm vs. The challenges of electrification in
2,000 rpm), which increases the prob- the transportation industry with new
lems with noise, according to Dr. Michael powertrain designs and aggressive
Platten, senior product manager and noise targets.
NVH specialist at Romax Technology. The challenge of understand-
The pressure is on manufacturers to pla- ing the effects of production vari-
KISSsoft examines the reliability of the system with
cate gear noise by analyzing data, opti- ability on gear noise and vibration its software tools.
mizing gear systems and testing results. performance.
“After decades of optimizing noise of The challenge to make everything
wind turbines and kitchen appliances, lightweight in automotive and aerospace dynamics simulation at AVL.
the focus switched to electric cars lately. sectors which is driven by efficiency “You’re looking at a variety of things
There is now a significant market for concerns, but has a significant impact on happening inside the transmission,
battery electric cars, with much higher gear noise and vibration. for example, when studying gear rat-
demands on low-noise gearboxes. In As software solutions continue to tle,” Schweiger said in a recent webinar
addition, there is always pressure on increase, gear noise can be better evalu- titled Efficiency and NVH Simulations
price in automotive. So, we now need ated through virtual, predictive and effi- for Transmissions. “There are repeated
low-cost, low-noise gearboxes,” said Dr. ciency coverage of the physics in the impacts caused by the movement of free
Stefan Beermann, CEO at KISSsoft AG. overall system, according to Christoph parts (loose gears, synchronizer rings)
Schweiger, team leader of structural within their active backlash. Another
important driver is the torque fluctua-
tion from the engine. You need to have a
gear contact model, study oil resistance,
the roller bearings, shaft flexibility and
housing flexibility. All of these things
must be considered in detail when calcu-
lating gear rattle.”
KISSsys, for example, is a gearbox
design software. Integrated into the
software are assessment functions that
evaluate the relevant properties of gear
meshes, the most important feature
being the contact analysis under load
which simulates the flank contact over
the whole meshing cycle.
“The important influence factors like
all involved stiffnesses (tooth, gear body,
shaft, bearing, housing), the exact tooth
shape, misalignments and tolerances,
are taken into account. Based on these
KISSsys includes assessment functions that evaluate the relevant properties of gear meshes which assessment functions, optimizations are
lead engineers to the best solutions.

automated and lead the engineer to the EV layouts, Romax works closely not rattle in transmissions.
best solutions for their current prob- just with gear and transmission engi- “The NVH Generation and Transfer
lems,” Beermann said. neers, but also with driveline integration process typically begins with an excita-
To meet the challenge of modelling and vehicle NVH teams. By linking to tion mechanism followed by amplifi-
and simulating the combined elec- other tools like multibody dynamics and cation, damping, transfer and then the
tric machine and transmission sys- whole-vehicle NVH simulators Romax response, result and assessment. Our
tem, Romax software lets the user build tools are being used by customers to research looks at whine and rattle in
a complete structural model of the look at gear whine and rattle under everything from passenger cars, trucks
full system and analyze the complete dynamic torque loading and predicting and tractors to industrial machinery,
dynamic behavior. directly how designs sound and feel at wind turbines and aircraft transmis-
“Gear mesh excitation forces are cal- the driver’s ear. sions,” said Schweiger.
culated directly in the software and close Schweiger at AVL explained the pro-
partnerships with electric machine mod- cess of determining gear whine and gear
elling tools like MDL Motor-CAD and
Cobham Opera allow seamless integra-
tion of the electric machine structural
model and electromagnetic excitation
forces with the transmission model.
In this way the effects of the electric
machine structure on gear noise can be
considered and likewise the effects of the
transmission dynamics on the electric
machine noise are taken into account,”
said Platten.
To address the issue of balancing
durability and efficiency with noise and
vibration performance in the high speed,
high duty environment of electric drive-
lines, Romax’s simulation tools provide
the ability to analyze and automatically
optimize all these performance targets
simultaneously. Romax customers like
GKN use this within a Right First Time
development environment to maximize
performance and quality of their EV
solutions.
“We’re moving into a new era of Manufacturers of:
hybrids and electric cars. Genuinely
high-performance products demand the
effective application of system knowhow
from concept to production, so you can
find the best possible balance,” said Theo
Gassmann, vice president, advanced
engineering at GKN Driveline.
“ The methodolog y used allows
advanced parametric studies to be car-
ried out in an all-in-one approach with
RomaxDESIGNER to consider the effect
of a wide range of design changes on and Universal Gear Company
efficiency at the same time as durabil- 1605 Industrial Drive
ity and NVH performance,” added Dr. Auburn, CA 95603
Artur Grunwald, supervisor, advanced Phone: (530) 885-1939
Fax: (530) 885-8157
geared systems calculations, GKN
Driveline.
For understanding the role of gear
noise within the context of today’s new
EV chassis designs and the seemingly
infinite range of proposed hybrid and

feature
Simulation & Testing A Systematic Approach and efficiently while reducing costs and
Testing and simulation play an impor- Beerman said that during the design energy consumption. You can’t focus on
tant part of the process even though phase, a systematic approach asks for one single area to get the best results.
many interviewed believe that this data a definition of macro parameters first The vibration of the entire system comes
is highly subjective and not always (for gears that would be parameters such into play when evaluating noise and per-
guaranteed. as module, number of teeth, pressure formance, according to Schweiger.
“With simulations the number of angle) and then a refinement by applying So how can you best identify and ana-
prototype tests is reduced. So, there is a micro modifications, like lead and pro- lyze noise issues when you may be utiliz-
huge gain in speed and cost reduction, if file modifications for gears. ing different people in different depart-
the number of tests can be minimized,” “Going to the second step too early ments that are responsible for NVH and
Beermann said. “Still, noise is a compli- means blanking out a large field of durability?
cated enough issue, that no simulation potentially much better solutions,” “Those people need to be educated in
can give a 100% guarantee that the pre- Beerman said. “For strength, this is each other’s areas and be provided with
dicted noise behavior is true. This means often not so critical, but for the higher the tools that help them to make sure
that the final step in the development demands on low noise gears this might they do no harm to each other’s aspects
must be a prototype test.” cause insurmountable issues.” of the design,” Platten added. “We must
Simulation is critical to ensure the best At Romax, Platten mentioned the ensure that the processes for model-
noise quality from the start. For too long “Right First Time” as a philosophy for ling and analysis are fast and robustly
noise and vibration has been considered CAE-led design. repeatable.”
as “something you do at the end to make “Nowhere is this more important than
it quiet”. Continuous simulation during in the consideration of noise and vibra- Selecting the Right Tools
all stages of the design allows engineers tion. Design decisions made right at the So, the take away here is that it helps if
to iron out problems before they become start — like tooth numbers and contact the software toolbox is diverse and the
problems. ratios - have the most impact on noise in staff is properly trained to utilize it to
“It is also the main driver in reducing the end while details like micro-geome- examine potential noise issues.
development time and costs by speed- try design that are considered later can KISSsoft, for example, offers public and
ing up design time and reducing pro- only really fine-tune what is already set in individual training about methods on
totyping cycles. It avoids the need for stone. It is therefore critical that consider- how to tackle noise problems with gears.
major remedial noise treatment late in ation of gear noise is considered system- “And we do noise optimizations for
the design when the opportunities for atically from beginning to end,” he said. gears ourselves, using these methods.
significant design changes are limited,” When dealing with gear noise in However, it is important to understand,
Platten said. transmissions, Schweiger believes there that there is not one optimal way to low
Platten continues, “Of course, testing are always tradeoffs. “Areas such as per- noise gears that always works. It is more
still plays a role — we can never elimi- formance, fuel consumption and emis- like an optimization process that might
nate prototyping completely — and in sions, temperature and thermal manage- go through several loops. The important
the electric vehicle world, we need to be ment, packaging, durability and costs part is to understand the mechanisms
sure that the simulations we are doing can be affected.” that generate noise and to know the
actually work by comparing them with It’s essentially a balancing act to get influence of the parameters controlled
real-world noise and vibration tests. the gearbox to run smoothly, quietly by the engineer,” Beermann said.
Once engineers have the confidence pro-
vided by correlation test, then simula-
tion-led design becomes the norm.”
Ultimately the “digital twin” concept is
what Romax is aiming for, where almost
all of the engineering design process
for transmissions and drivelines is test-
free and the prototyping phase becomes
merely a verification exercise. To achieve
this, you need to have engineering
design processes — not just for noise and
vibration — that work across CAE tools,
across departments and even between
different organizations (OEMs and sup-
pliers, for example).
“Our strategy is to concentrate our
efforts as much on streamlining and auto-
mating the process as we do on providing
simulation technology,” Platten added.
Romax follows a "Right First Time" philosophy for CAE-led design, according to Dr. Michael Platten.

“In KISSsoft, we have integrated tools example, gear contact through interac- with the Gear and Power Transmission
and algorithms that help with the assess- tions with tribological factors,” Platten Research Laboratory for over 10 years.
ment of gear noise. In addition, we offer said. Researchers at Politecnico di Torino and
interfaces to dedicated vibration soft- Additionally, work is needed to simu- TU Darmstadt have both also published
ware, for deeper analysis. With this, the late vibration and noise of structures work on their use of Romax software for
user gets the best of two worlds, an easy at very high frequencies, where the simulation of gears in novel applications:
to use gear design software and a soft- FE starts to break down, to investigate the former on optimization methodolo-
ware that is specialized on vibrations, energy methods which give less detail gies for lightweight gears produced by
but not on gears,” he added. but provide better ability to make engi- additive manufacturing techniques using
Working alongside the Romax tools neering decisions about high frequency RomaxDESIGNER simulation, and the
for gear whine analysis and electric behavior and which take into account latter on investigating novel concepts for
machine noise, the company also pro- inherent variabilities at high frequencies. range-extended electric vehicles,” Platten
vides interfaces and links to a number “For gear noise, Romax has worked said.
of other tools which support design for
gear noise and help customers to cre-
ate integrated and automated CAE
processes:
Interfaces for gear contact analy-
sis and transmission error calculation Where AEROSPACE Gets Its
LIFT
which support our own contact simula-
tions: OSU Gearlab LDP for helical gears.
Ansol, Gleason CAGE and Klinelnberg
KIMoS for bevel and hypoid gears.
Interfaces to FE tools like MSC Nastran,
Altair Optistruct, Ansys and NX Nastran
for pre- and post-processing of compo-
nents like housings and complex shafts for
dynamic simulation of gear noise
Interfaces to acoustic radiation tools
like LMS Virtual.Lab Acoustics, MSC
Actran and Ansol Coustyx
AVL offers software suites such as AVL
Excite, software for the simulation of
rigid and flexible multi-body dynamics
of powertrains. It is a specialized tool
that calculates the dynamics, strength,
vibration and acoustics of combustion
engines, transmissions and conventional
or electrified powertrains.
AVL Fire is a CFD simulation tool in
the field of combustion analysis. It spe-
cializes in the accurate prediction of all
IC Engine relevant processes includ-
ing injection nozzle flow, fuel injection,
combustion, emission and exhaust gas
aftertreatment. The software also sup- Aerospace is striving to reach new heights. We’re a power
ports the development of electrified in aerospace gear production, with an unparalleled precision
powertrains and drivelines. gear facility, over 60 years of aerospace gear experience –
and Aerospace AS 9100 compliance.
Collaborate and Innovate
“The best way to meet the multitude of Aim higher, go farther,
with aerospace gears from
challenges discussed in this article is to
Forest City Gear.
tackle issues such as fundamental valida-
tion of the methods for simulating gear
Excellence Without Exception
noise, which have worked previously
for conventional drivelines, but which
are now being pushed due to increased 8 1 5 .6 2 3 .2 1 6 8 | www.forestcitygear.com
speed, and the subsequent impact on, for

feature
The outcome of projects with institu-

tions such as Ohio State’s Gear Lab or
the FZG in Munich often are the basis
for standards and also go into commer-
cial software such as KISSsoft.
“In the gear world, the topics of
strength, efficiency and noise will
always benefit from close cooperation
between industry and universities,” said
Beermann.
All in all, gear noise is just one of
many design challenges that pop-up
in a variety of industrial applications.
The automotive industry is a focal point
today as we discuss electric vehicles,
mobility and new transmission and effi-
ciency requirements. In a few years,
there will be another area where soft-
ware providers will need to develop new
innovative, solutions.
Who knew that being quiet could be
quite so complicated?
For more information: After decades of focusing on gear noise in wind turbines and kitchen appliances, the focus has
AVL North America switched to automotive and vehicle applications, according to Dr. Stefan Beermann at KISSsoft.
Phone: (734) 459-3426
www.avl.com
KISSsoft AG (Gleason Corporation) For Related Articles Search
Phone: +41 55 254 20 50
www.kisssoft.ag software
Romax Technology at www.geartechnology.com
Phone: (248) 220-1201
www.romaxtech.com
Where you can watch and listen to real gear industry
LIVE!
experts explaining the latest gear technology.
ASK-THE-EXPERT
Learn about the basics by watching “Ask the Expert LIVE!”
and find out more about the latest and upcoming technology
by watching our recorded interviews.
www.geartechnology.com/tv/
SEASON 2 RELEASED!
• Cylindrical Gear Cutting
• Gear Design
• Gear Inspection
• Ask Anything

Manufacturing sMart
SHARP
WE ARE A LITTLE HOBS EDGY......
When it comes to your productivity
Change Downtime To Productivity
6K Products
New insert tooling to cut precision
blind or open end splines and
straight or tapered keys in standard
machine tools.
You Need Your Tools Back FAST
Gear manufacturers need tools
– Eliminating Downtime &
returned
• Stripping & Re-Coating
quickly.
Tuned Weorsharpen
To Meet Surpass your perishable
• Gear Shaperassets
Sharpening
to meet
Original or surpass
Design Specs original sharpening
• Milling Cutter Sharpening
andspecifications… rapidly
That’s Where We Come In . That is Tool
• Gear whatCertifications
we do.
Enabling our customers to continually cut
teeth since 1999.
• HOB SHARPENING
• SKIVE CUTTER SHARPENING
• BROACH
Tel: 216-642-5900 SHARPENING
• Fax: 216-642-8837 • 5755 Canal Road • Valley View, OH 44125
• STRIPPING
Email: & RECOATING
gallen@gallenco.com WWW.GALLENCO.COM
360-264-2141
WWW.GALLENCO.COM
216-642-5900 6kproducts.com
Fax: 216-642-8837 • Email: gallen@gallenco.com
5755 Canal Road, Valley View, OH 44125 sales@6kproducts.com
Emergency Gear Replacement

Complete Spur & Helical Gears & Pinions
1/2”(12mm) - 59”(1500mm)
2-4 Day Turnaround for Gear Grinding
810-765-8302 • 1390 South Parker, Marine City, MI 48039 Quotations to: rfq@splineandgear.com
Industries Served: • Mining

• Oil & Gas • Steel
• Machine Tool • Paper
• Electrical • Mixing

Manufacturing sMart
Sharpening Services
- Hobs
- Milling Cutters
- Shaper Cutters
The
- Shaving Cutters
- Broaches
Power
of One2
Service Centers
Hoffman Estates, IL
Phone: 847.649.1450
Your Objective:
Fax: 847.649.0112 One face in perfect alignment with another. For infinity.
East Tawas, MI
Phone: 989.362.0414
Fax: 989.362.2720
Querétaro, Mexico
Phone: 52 442 217 34 45
Fax: 52 442 217 34 46
sales@star-su.com
www.star-su.com
No problems. No distress. No delays.

That’s the same objective you have for choosing your gear producer.
Circle Gear’s objective is to engage with every customer’s objectives.
sales@nordex.com
eng@nordex.com One to 1000 gears
(203) 775-4877
Customer designed or reverse engineered
ISO Certified / ITAR Gearbox repair, rebuild or redesign
Registered / Trace Certified OEM or end-users
ISO 9001:2015 Certified
• Standard Components
• Made to Print Parts
• Design & Engineering 1501 S. 55th Court, Cicero, IL 60804
• Gears, Pulleys & Racks (800) 637-9335
• Assemblies (708) 652-1000 / Fax: (708) 652-1100
sales@circlegear.com
www.circlegear.com
Spiral and Straight Bevel Gears (Cut, Ground or Lapped) • Spur Gears • Helical Gears •
Long Shafts • Herringbone Gears • Involute and Straight Sided Splines • Internal Gears •
Worm and Worm Gears • Racks • Sprockets • ISO Certified
Partnering with QualityReducer to provide
Nordex.com Gearbox repair, rebuilding and reverse-engineering.

Archeology
Just Got Easy
Gear Technology is happy to report that every issue
(1984 to present)
is now available online at
www.
geartechnology
.com.
Need articles on software, gear grinding,
plastics, or lubrication?
Put away your shovel...
They’re simply a keyword away.
Drop by our website to uncover decades of peer-

reviewed technical and back to basic articles
You don’t need to be an archeologist to “excavate”
the information that matters to you.
www.geartechnology.com/issues.
Innovative
grinding fluids
to get your
production into gear.
oelheld U.S., Inc.

1100 Wesemann Dr
West Dundee, IL 60118
phone: +1–(847)–531-8501
fax: +1–(847)–531-8511
E-Mail: hutec-us@oelheld.com
www.oelheld.com

ask the expert
Selecting the Right Tooth Email your question — along with your name,
Thickness job title and company name (if you wish to

remain anonymous, no problem) to: jmcguinn@
geartechnology.com; or submit your question by
visiting geartechnology.com.
QUESTION
We are currently revising our gear standards and tolerances, and a few problems
with the new standard AGMA 2002-C16 have arisen. Firstly, the way to calculate
the tooth thickness tolerance seems to need a “manufacturing profile shift
coefficient” that isn’t specified in the standard; neither is another standard
referred to for this coefficient. This tolerance on tooth thickness is needed later
to calculate the span width as well as the pin diameter. Furthermore, there
seems to be no tolerancing on the major and minor diameters of a gear.
Expert Response provided by coefficients, but almost any other

John M. Rinaldo. AGMA 2002-C16 specification of tooth thick-
does not specify any tolerances; it is up ness to other ways of specifying
to the designer to select the tooth thick- tooth thickness or to measure-
ness and tolerance, or maximum and ments that can be checked when
minimum tooth thickness, appropriate the parts are manufactured. For
for the application. The designer must example, if the maximum/mini-
also select the tolerances for the major mum transverse tooth thickness
and minor diameters of the gear. is specified at a given diameter,
Figure 2 Measurement over balls from AGMA 2002-
equations are provided C16, Figure 10.
to find the maximum/
minimum normal cir- backlash, but requires the tooth thick-
cular tooth thickness at the ref- ness to be measured in relation to the
erence diameter. Then the maxi- datum axis. Such measurements are typi-
mum/minimum acceptable mea- cally performed on a double flank tester,
surement over balls or any of the a gear measuring machine, or from a
other measurements covered can datum surface to a single pin or ball.
be calculated with the equations Tooth thickness and backlash are inti-
provided. mately related, which is why AGMA
AGMA 2002-C16 also provides 2002-C16 covers both topics in a single
methods to determine tooth thick- standard. In establishing tooth thick-
ness based on measurements that ness, the goal is generally to ensure that
are indirect. For example, if a span the expected range of backlash will be
measurement is taken, then the appropriate for the application. In many
normal circular tooth thickness applications — particularly when rota-
at the reference diameter can be tion is unidirectional — backlash is not
Figure 1 Span measurement from AGMA 2002-C16,
Figure 7. (All graphics courtesy of AGMA.) found using Equation 67. particularly important. In these cases,
Although AGMA 2002-C16 allowing a wide range of backlash and,
The manufacturing profile shift coef- does not specify tolerances for tooth therefore, a large tooth thickness tol-
ficient — commonly referred to as “the thickness, annexes B and C provide erance, will keep manufacturing costs
x factor” — is not required by AGMA guidance on establishing tooth thick- down. When tight control of backlash
2002-C16. In fact, if the manufacturing ness specifications in either the nom- is required, as in indexing applications,
profile shift is known, the only thing inal or functional system. The nomi- then not only does the tooth thickness
it is used for is to calculate the normal nal system is more commonly used, and need to be tightly controlled, but the
circular tooth thickness at the refer- allows measurement over pins or balls or other gear tolerances may also need
ence diameter. The standard provides with span. The functional system allows to be tighter to allow the tooth thick-
methods to convert not only profile shift a more direct calculation of expected ness tolerance to be met. The gear tooth

Want More Ask the Expert?
Try Gear Technology TV to watch our video sessions of
Ask the Expert recorded live at Gear Expo!
www.geartechnology.com/tv/
Figure 3 Chordal measurement from AGMA

2002-C16, Figure 21.
thickness measuring method may also
FORGING
need to be carefully chosen, since the
method selected can affect both the abil-
ity to tightly control the tooth thickness
and manufacturing cost. For example,
for a large gear a chordal tooth thickness
AHEAD
measurement can provide a quick and
inexpensive measurement, but unless the
radius to the outside diameter has been
accurately determined from the datum
surfaces, there will be a considerable
uncertainty in the calculation of func-
tional tooth thickness. Measurement of
pitch on a gear measurement machine
OF THE PACK
will give a direct measurement of func-
tional tooth thickness, but at a high cost.
Double flank measurement can be used
to quickly measure the functional tooth
thickness of all the teeth on a gear, but
generally is only applicable to small gears
produced in high volumes.
The selection of the appropriate range
of tooth thickness is no easier than the
selection of any of the myriad other
choices the designer faces, such as select-
ing the appropriate numbers of teeth, the
module, the helix angle, the face width,
the material and heat treatment and the
elemental or composite tolerances.
Fast.
No Fine Print.
John M. Rinaldo is a retired senior
development engineer (Atlas Copco Comptec), No Premium.
a current member of the AGMA Accuracy
Committee, and U.S. delegate to the ISO At McInnes Rolled Rings, we provide quality
Accuracy Committee. products, shipped fast. And we partner that with
exceptional customer service to forge the perfect
partnership with our customers.
For Related Articles Search
inspection
at www.geartechnology.com
1.877.695.0280  www.McInnesRolledRings.com

technical
Predicting Life on Through Hardened

Steel Rack and Pinion for Jacking
Applications in the Offshore Industry
Adrian Nowoisky
(The statements and opinions con-
tained herein are those of the author and
should not be construed as an official
action or opinion of the American Gear
Manufacturers Association.)
Introduction in Industry and Application

Requirements
Lift boats and jack-up drill rigs are able
to self-elevate the hull from sea level.
These vessels use either a pin-and-yoke- Figure 1 Liftboat illustration.
type jacking system or a rack-and-pinion
system to raise or lower the hull. These perhaps causing loss of the vessel or even cutting process. The rack will be welded
applications are used for every kind of lives. The main gear characteristics of to the leg structure that can be 250–300
off-shore service, installation or explo- a rack-and-pinion application are: low ft. (76.2–91.4 m) tall for a lift boat. An
ration — mainly in the energy industry. speed, high torque and a low number example of the rack material is ASTM
There will be more attention payed to the of load cycles. Furthermore, it can be A514 high-strength steel (1.8974 per EU
challenges of the definition and analyza- stated that the contact stress level of a grade). In most applications the mate-
tion of a rack-and-pinion-type system. rack-and-pinion is starting where the S-N rial selection is driven by the certifying
Unlike an enclosed gear mesh, the jack- curve of ISO and AGMA standards end. body and therefore special steel selections
ing part is exposed to sea water and other However, to have confidence in their own are made based on the rules and recom-
influences in an offshore environment. gear design and to satisfy the certifica- mendations of the certification body. The
Only biodegradable grease is used for tion body, a different approach must be pinion typically is made out of 4340H
the rack-and-pinion, depending on the taken in order to justify the acceptance of (1.6511 DIN) as through-hardened mate-
architecture, with an automatic lubrica- such high contact stresses in these unique rial, or some applications use carburized
tion system. To give an idea of the scope applications. materials such as 1.6587 18CrNiMo7-6
of such gearbox and pinion size, Oerlikon Material and mechanical properties (close to AISI 4320).
Fairfield is manufacturing its largest typical for this application. The rack For the sizing example given in the fol-
gearbox for such vessels with a ratio of material is a high-strength, through- lowing pages, these materials and mate-
7764:1 and weight of close to 11 metric hardened material that is purchased as a rial properties are used as specified:
tons. A matching pinion for this gearbox
would have a weight of 3 metric tons and Pinion Rack
Material: 4340H ASTM A514 Grade Q
a module of 95–110 mm. In the offshore
Heat treatment: Quenched and tempered Quenched and tempered
industry these pinions are made with 7–8 Surface Hardness: 36–40 HRC 21–23 HRC
teeth, and a typical pressure angle of 30˚ Min. Tensile strength: 160 ksi [1103 N/mm2] 115 ksi [793 N/mm2]
for the mechanical benefits known and Min. Yield strength: 140 ksi [965 N/mm2] 90 ksi [620 N/mm2]
published (Ref. 1). Designing and sizing SN curve: Steel, Grade 2 HB300 AGMA Steel, Grade 2 HB200 AGMA
a rack-and-pinion system, per AGMA Through-hardened steel,
Through-hardened steel, alloyed
alloyed
and ISO gear calculation, is challeng-
ing when it comes to predicting the gear
life on contact stress. The main focus on max. 8 in. (203.2 mm)-thick steel plate. Operation of a lift boat. As stated,
the gear calculation is to satisfy the root The teeth geometry is generated in a the typical duty for a lift boat is moving
bending strength with sufficient safety flame cutting process and smoothed with to the work area to elevate the hull for
margin to the load spectrum. The rea- a grinder. There are racks that undergo a more stability (Fig. 1). In Figure 1 two
son for this is the severity of such failure, machining process after the flame plate images illustrate the lifting of the hull
Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Fifth Floor, Alexandria, VA 22314-1587. Statements
presented in this paper are those of the author(s) and may not represent the position or opinion of the American Gear Manufacturers Association.

above sea level. For a solid stand, the legs Table 1 Example load spectrum
[in-lbs] [Nm] [rpm] [h]
are designed with pads at the bottom.
Leg operation 331,901 37,500 3 750
These pads are supposed to penetrate Hull operation 560,252 63,300 1.5 140
the sea floor for a more stable stand. This Preload operation 725,761 82,000 0.75 140
enables the platform to stay firm during Preload holding 858,522 97,000 - ‑
operation, as well as in rough weather Storm holding 1,097,492 124,000 - ‑
conditions. Test load 1,287,784 145,500 - -
Loads and duty cycle. The loads are
Table 2 Rack-and-pinion geometry
separated in static loads under calm and
Description Symbol Unit Pinion Rack
moderate weather conditions, and com- Normal module m mm 28.578
bined loads where weather conditions Normal pressure angle αn DEG 30
are taken into account to the operational Helix angle βn DEG 0
loads. In most cases the certification Number of teeth z 1 8 256
body is ruling out load cases for review. Profile shift coefficient x 1 0.1881 0.0000
In the current example, we will review Face width b mm 165.100 127.000
Tip diameter da mm 292.100 165.100
the static loads from:
Pitch diameter mm 228.923 144.832
• Leg operation — lifting and lowering Root form diameter dNf mm 200.746 119.700
only one leg Base diameter db mm 197.993 ‑
• Hull operation — lifting and lowering Contact ratio εα 1 1.117
the complete hull
• Preload operation — extra weight taken
into account
• Leg and hull holding — static loads only
And combined loads are taken into
account as well, such as:
• Preload holding — hull elevated with
extra loads from the environment
• Storm holding — hull is elevated and
high waves hit the elevated vessel
• Test load — test load according to certi-
fication body rules
Rack-and-pinion geometry. A rack-
and-pinion geometry was chosen from
the Oerlikon Fairfield product line, since
there is a substantial history in service
as well as fundamental analytical work
done to this system over the time of ser-
vice and recertification process. The main Figure 2 Root bending stress evaluation per ISO 6336.
characteristics of rack-and-pinion system Table 3 Root bending stress results
are shown in Table 2. ISO 6336:2006 Method B AGMA 2001-D04
σF_Pinion σF_Rack St_Pinion St_Rack
Analytical Evaluation [ksi] [N/mm2] [ksi] [N/mm2] [ksi] [N/mm2] [N/mm2]
This section will show and discuss the Leg operation 37.49 258 51.64 356 35.10 242 ‑
results according to gear calculation stan- Hull operation 63.28 436 87.16 601 59.26 409
Preload operation 81.97 565 112.91 778 76.76 529
dards. As well, it will briefly discuss a
Preload holding 96.96 669 133.57 921 90.80 626
theory based on Brinell stress to quantify Storm holding 123.96 855 170.74 1,177 116.08 800
the life of rack-and-pinion systems for Test load 145.45 1,003 200.35 1,381 136.21 939
the contact life.
ISO 6336 vs. AGMA 2001-D04 root
bending stress assessment. The calcu- discussed further here. The results are
lation is performed according to ISO showing throughout the load cases high
6336: 2006 Method B, and AGMA 2001- root bending stress. In Figure 2 we see
D04 root bending stress calculation sufficient root bending life for the S-N
(Refs. 2–3). It was chosen to use both curves. The root bending stress is still
methods, since the ISO calculation takes within the limits of the material strength;
a rack or internal gear for root bend- details of these analyses are shown in
ing stress into account. The differ- Table 3.
ences between each standard will not be

technical
In comparison, it is significant how is the most important step in the design ISO 6336-2. Comparing the permissible
much higher the permissible root bend- process. It is necessary to be aware of contact stress with the results in Table 5,
ing stress is between pinion and rack. required safety factors from certification we see approximately 1.5 to 3.45 higher
In the previous material section of this bodies as published (Ref. 4) or through contact stress throughout the load spec-
paper, it was pointed out that the rack personal experience. trum. Figure 3 is showing the appropriate
material is almost 30% less durable than ISO 6336 vs. AGMA 2001-D04 contact S-N curve with the load spectrum. Here
the pinion. The higher root bending stress assessment. The calculation was we see the challenge for the gear designer,
strength can be explained with the cal- done similar to the root bending stress i.e. — to find appropriate acceptance cri-
culated notch sensitivity factor YdrelT assessment using (Ref. 5) and (Ref. 3) teria for the high contact stress. Based on
that with 1.6 is adding significantly to the standards. The permissible contact stress the results, this design would fail due to
permissible root bending strength of the for leg operation is specified with σHP_ high contact stress. There are factors in
rack. It should be pointed out that pay- Pinion
= 209.14 ksi (1,442 N/mm2) and σHP_ the ISO standard accounting for a work
ing attention to safety on root bending Rack
= 166.79 ksi (1,150 N/mm2) based on hardening factor Zw that can increase the
permissible contact stress σHP of an appli-
Table 4 Permissible root tooth stress per ISO 6336 cable range of 2% to 16%. If taking best-
Pinion Rack case work hardening factors into account,
Permissible root stress, σFP
[ksi] [N/mm2] [ksi] [N/mm2] it will not meet life acceptance criteria
Static loads 79.77 550 178.97 1234
per gear calculation standard. However,
Combined loads 170.27 1174 230.46 1589
in this application the work hardening
Table 5 — Contact stress results factor will be taken into account with
ISO 6336:2006 Method B AGMA 2001-D04 1.0. If this design has to be submitted to a
σH Sc certification body, how can be these high
[ksi] [N/mm2] [ksi] [N/mm2] contact stresses deemed as acceptable for
Leg operation 280.23 1,932 292.54 2,017 service?
Hull operation 364.08 2,510 380.08 2,621
The contact analyses shown in Figures
Preload operation 414.39 2,857 432.59 2,983
Preload holding 450.70 3,107 470.50 3,244 4 and 5 assume ideal alignment and sur-
Storm holding 509.57 3,513 531.96 3,668 face contact condition. As mentioned in
Test load 551.99 3,806 576.24 3,973 the introduction according to the gear
calculation standards of ISO and AGMA,
this gear set has a limited life prediction
due to high contact stress.
Brinell theory. In 2010 a differ-
ent approach was published by A.N.
Montestruc to evaluate high-contact
stress on rack-and-pinion systems in the
offshore industry (Ref. 6). This theory
is based on the Brinell hardness mate-
rial test method founded by the Swedish
engineer Johan August Brinell in 1900
(Refs. 9–10). The hardness of a given
material is evaluated with a spherical test
object made out of sinter hard metal and
Figure 3 Contact stress for rack-and-pinion. forced into the test material. The plastic
deformation in the test material can be
evaluated while measuring the plastic-
deformed diameter in the test material.
Either the indentation or a table (Ref. 7)
can be used to build the relationship
between impression diameter caused by
the test force to calculate the theoretical
contact stress that is described as “Brinell
stress” by Montestruc and defined in
Equation 1:
F (1)
σBR =
π 2
D
4 i
Brinell stress represents the stress when
the material will start to flow. This theory
Figure 4 Contact stress for pinion. Figure 5 Contact stress for rack.

had limitations on material and gear
geometry unique to this application, as
well as a low number of load cycles, that
is less than 10,000. This paper (Ref. 6)
is proposing an allowable stress calcu-
lated for jacking applications based on
the Brinell stress (Ref. 1) while using the
factor –0.056 and 1.40 from Figure 17
out of the AGMA standard (Ref. 3). This
equation enables the engineer to predict
the life of his rack-and-pinion system.
σA = 1.40 (σBR)(N–0.056) (2)
As shown in Figure 6, the allowable

contact stress is significantly higher than
the allowable contact stress out of the ISO
or AGMA gear calculation. Due to the
low number of cycles the S-N curves are
in the linear static area.
This theory was never validated or fur-
ther investigated by a standardization Figure 6 Allowable contact stress for rack-and-pinion.
organization. This approach might be a
help to find limits and guidelines for this
kind of gear application. This method is
mentioned to draw a complete picture of
this technical problem.
Numerical Evaluation
FEA will be performed to see how high
the von Mises stress is, and how deep
the von Mises stress penetrates into the
material, as well as whether there is any
other stress factor like shear stress that
contributes significantly to van Mises
stress. Oerlikon Fairfield can perform a
linear FEA analysis using ANSYS R18.1
to evaluate this rack and pinion design.
It is preferred to carry out in the future a
non-linear FEA analysis since experience
is showing that this application operates
in the stress level of plastic deformation.
Root bending stress validation.
To validate the FEA model (Fig. 7) the Figure 7 Root stress at the pinion at severe storm load.
root bending stress on the pinion will
be calculated at severe storm holding.
The result of the root bending stress is
showing a good correlation. The spread
is 5–10% between FEA simulation and
standard calculation.
For Related Articles Search
gear life

technical
Linear FEA at storm holding:
Figure 8 FEA model principal stress. Figure 9 Storm holding shear stress.
Figure 10 Storm holding contact stress. Figure 11 Storm holding von Mises stress.
Linear FEA at preload operation:
Figure 12 Preload operation principal stress. Figure 13 Preload operation shear stress.
Figure 14 Preload operation contact stress. Figure 15 Preload operation von Mises stress.

Figure 16 Stress components below the surface along the load axis (for ν = 0.3).
For this FEA, more attention is payed parallel cylinders (Fig. 16) for materials Conclusion
to the details of stress directions and with a Poisson’s ratio ν = 0.3 (Ref. 14). As pointed out earlier in this presenta-
depth to the surface to get a better feel In Figure 16 we can see a fairly good tion, there is a good correlation between
for what is happening within the mate- correlation between the FEA princi- FEA results and the contact stress theory
rial. For the load cases, storm holding, pal stresses in the x, y, and z direction, for two cylinders for materials with a
and maximum preload operation, the as well as the shear stress. The results Poisson’s ratio of ν = 0.3. The use of the
results are shown of the FEA calculation of the FEA for the von Mises stress are Brinell theory (Ref. 6) is suitable and
in Figures 8–15. And the following details below the theoretical values, but follow appropriate to evaluate rack-and-pinion
are looked into: the same pattern. As expected, the prin- designs. It is the author’s understanding
• Figures 8, 12 — principal stress cipal stresses are high compared to the and supposition that the high-contact
• Figures 9, 13 — shear stress allowable contact stress defined by gear stresses are starting to deform the rack-
• Figures 10, 14 — contact stress standards. and-pinion right away. After a few “run-
• Figures 11, 15 — von Mises stress in” cycles, cold work hardening (Ref. 8) as
Figure 8 illustrates the rack-and-pinion Validation and Testing well as the rack deformation in width and
model, sectioned in the middle of the Since 2003 Oerlikon Fairfield has shipped concave shape will retard wear and defor-
rack to grasp the centered point of con- more than 750 certified gearboxes that are mation significantly. After a few runs
tact. In the FEA model a small crowning equipped with this particular rack-and- the rack-and-pinion contact is no longer
was applied to avoid stress peaks on the pinion. Together this jacking system is on a line of action; it will become more a
end of the rack. It can be assumed that more than 17 lift boats in service. Up to “moving contact area” and a “mesh bal-
this is the highest stressed area that the this writing the rack-and-pinion are work- ance” will take place. It is not unusual
rack will experience through operation ing properly and without any known fail- to see deformation in depth of more
and according to the FEA. ure due to fatigue or high-contact stresses. than 5 mm (0.2 in.) and width of 15 mm
The contact stress calculated with The certification body ABS (American (0.65 in.) on both sides of the rack after
the FEA doesn’t correlate as accurately Bureau of Shipping) has statically tested test load is applied to rack-and-pinion.
with the analytical calculation as with the system gearbox and rack-and-pinion Figures 17–18 show the rack before
root bending stress. However, the lower before issuing product design approval. and after the test load for the ABS certi-
stresses can be reasoned with the area The static test is typically defined by ABS fication process. The deformation is so
of contact in the FEA model compared and performed under the supervision of high that it is visible and could be mea-
to the theoretical line of contact at gear surveying engineers. After this test all sured with a tape measurement.
standard calculation. Furthermore, the parts are subjected to non-destructive Figure 19 (Ref. 11) is showing a rack
FEA calculation has not used any applica- crack detection to verify the soundness from a lift-boat removed due to manda-
tions factors as typically assumed in the of the system. The acceptance criteria are tory leg inspection after more than 10
gear calculation algorithm. simple, i.e. — no cracks are allowed after years of service, according to govern-
In fact, the results are giving a good the test is completed. It can therefore be ment requirements (Ref. 12). Figure 20
scope to explain what is going on in the concluded that the rack-and-pinion sys- (Ref. 11) is showing a rack with proper
rack material and match the Hertzian tem has a substantial service experience lubrication for service. As we can see, the
contact stress distribution theory for two and is well designed for service. rack teeth are visually deformed and far

technical
Figure 17 Test rack prior to test load. Figure 18 Test rack post-test load.
Figure 19 Rack removed from hull. Figure 20 Greased rack for operation.
from an ideal gear mesh — but accept- and loss of vessel could mean on such 7. “Steel Hardness vs. Strength.” www.engineer-
ingtoolbox.com/bhn-brinell-hardness- number-
able for the intended use of lifting and platforms is described (Ref 13). This gives d_1365.html
lowering legs and hull. It can be con- the engineer and certifying bodies a huge 8. Octrue, Dr. Michel, 2016 “Contact Fatigue
cluded that contact stress per gear calcu- responsibility to carefully review their Characterization of Through-Hardened
Steel for Low- Speed Applications — Like
lation up to 456.87 ksi 3150 N/mm2) are work and ensure the design is properly Hoisting” AGMA FTM16, Technical Centre for
still within the range of a good working working in service. Mechanical Industries, p. 12, 2016.
rack for low life cycles 400 ≤ N ≤ 10,000 9. ASTM E10–14. Standard Test Method for Brinell
Hardness of Metallic Materials.
cycles. Simulation technology becomes a References 10. ISO 6506-1:2014. Metallic Materials, Brinell
sophisticated tool to predict material and 1. Miller, Rick. “Designing Very Strong Gear Teeth Hardness Test — Part 1: Test Method.
by Means of High Pressure Angles,” AGMA 11. Pictures courtesy of SEMCO LLC. Marine
mechanical behavior of rack-and-pinion. FTM16, Innovative Drive Solutions LLC, p. 2 2016. Engineering and Construction
In particular, the linear and non-linear 2. ISO 6336-3:2006. Calculation of Load Capacity 12. “United States Coast Guard — Guidance on
FEA can help to understand the con- of Spur and Helical Gears — Part 3: Calculation the Inspection, Repair and Maintenance of
of Tooth Bending Strength. Liftboats/
tact stress and deformation much better. 3. ANSI/AGMA 2101-D04. Fundamental Rating 13. CG – 543 Policy Letter.” www.uscg.mil/hq/cgcvc/
Engineering judgement and experience Factors and Calculation Methods for Involute cvc/policy/policy_letters/543/CG-543_pol07-02.pdf.
are required to determine what can be Spur and Helical Gear Teeth (Metric Edition). 14. Marine Accident Report: NTSB/ MAR — 13/01
4. ABS Mobile Offshore Drilling Units. Part 6, PB2013-106633
acceptable and what’s not. However, to Chapter 1, Section 9 — “Jacking and Associated 15. www.ntsb.gov/investigations/AccidentReports/
this day there exist a lot of jacking vessels Systems” p. 80, 2016. Reports/MAR1301.pdf, p.14.
in the fleet, but there is not the complete 5. ISO 6336-2:2006. Calculation of Load Capacity 16. Ugural, A.C. and S. K. Fenster. Advanced
of Spur and Helical Gears — Part 2: Calculation Mechanics of Materials and Applied Elasticity,
understanding of all factors and behav- of Surface Durability (Pitting) + Corrigendum Fifth Edition, p.163.
ior of the system. It needs more research ISO 6336-2/AC1:2008.
of these particular applications to gain 6. Montestruc, A.N. “Allowable Contact Stresses
in Jacking Gear Units Used in the Offshore
a better understanding as to why con- Industry,” Gear Technology, 2010.
tact stresses of 450 ksi (3102 N/mm2) for
preload operation and 550 ksi (3792 N/
mm2) for test load is working properly in Adrian Nowoisky is currently a senior product engineer at Oerlikon
the industry. For the design engineer the Fairfield, specializing in designing custom gearboxes for various industrial
applications. He also is assigned to analyze and optimize detail gear geometry
main focus should be to satisfy safety on for spur and helical gear sets. He earned his Dipl. Ing. (FH) degree from the
root bending strength for the system. It is Anhalt University of Applied Sciences in Koethen, Germany in 2005. In his
preferred to have a jammed system due to professional experience of more than 12 years, he took part in developing
deformation, rather than an uncontrolled a dual-clutch transmission at ZF Getriebe GmbH;accessory gearboxes for
jet engines with Rolls-Royce Deutschland; and currently jack-up industrial
descent of a lifted hull in open waters. gearboxes. Nowoisky also gained experience in the naval industry as design engineer for
Based on actual events, what a fracture submarine outfitting at the ThyssenKrupp Marine Systems shipyard in Kiel, Germany.

Skiving Machining Center
for Gears - GMS450
Integrated - Skiving
Drilling
Turning
Skiving Lathe Drilling
• High Efficiency Gear Skiving Reduces Work Time up to 1/5 (compared to gear shaping)
• Proprietary Technologies Used
• High Precision Machining of Hardened Gears
• Easy to Control Tooth Profile
• Compact, yet can Machine up to 450mm Diameter Part
Nachi America Inc.

715 Pushville Rd., Greenwood, IN 46143
317-530-1007 • www.nachiamerica.com
technical
Human Machine Interface (HMI) in Gear

Manufacturing
“Documentation is not a Substitute for an Intuitive Interface”
Yefim Kotlyar
Introduction and Cursory Historical Overview there are still some mechanical gear cutting machines in the
(Giving credit where credit is due, the quote contained in this field, they are increasingly being phased out, as very few (if any)
paper’s title is attributed to Kenneth Corless.) mechanical machines are being produced today anywhere in the
Human machine interfaces (HMI) in the gear industry are world. As compared to turning and milling, it did take a bit lon-
continuously influenced by the advances of user interfaces ger for the gear manufacturing industry to fully embrace com-
elsewhere in computing. The ever-friendlier and more intui- puterization, but once it did, it never looked back.
tive interfaces being perpetually enhanced by Google, Microsoft, During most of the 20th century, improvements of gear
Apple, Facebook, and all other technology leaders are influenc- manufacturing machinery were centered on perfecting the art
ing and changing the expectations of the machine users. The of the machine’s mechanical foundation, i.e. — increased rigid-
machine tools makers are becoming more cognizant of this ity; improved accuracy of the axes alignments; introduction of
trend and are making strides to improve their HMIs to meet the mechanisms for reduction — and even elimination of backlash;
changing expectations. introduction of the differential mechanism for cutting heli-
These days gear manufacturing is mostly computerized. While cal gears; and introduction of the rolling bands for precision
gear grinding (Fig. 1) are just some examples. Also, the use of
hydraulics and pneumatics was expanded to support various
machine functionalities.
Machine computerization at the end of 20th century brought
a new wave of profound and non-stop innovations into the
world of gear manufacturing. At the beginning of this com-
puterization process in 1980s and 90s, most of the innovations
were driven by computer hardware, i.e. — more powerful, faster
controls. But eventually, as Microsoft co-founder Paul Allen
said — “Software trumps hardware” — software development
has been playing an increasingly greater role in generating new
advancements.
The 21st century innovations, whether the expansion of
machine functionalities or the elevation of friendliness mak-
ing the machines easier and therefore faster to set up/operate,
are only limited by the imagination of machine users and mak-
ers. Thankfully, many users are not shy about verbalizing their
imagination and are dispensing new challenges to the machine
makers that add fuel to their creative process.
Today, almost anything one can imagine can be mathemati-
cally and logically modeled. If an idea can be modeled, it can be
turned into a computer code to run the machine.
One side of this unrelenting expansion of machine features,
options, and new capabilities is the inevitable expansion of
HMI. However, despite the proliferation of features and options,
the machine should not be more difficult to operate. Users’ high
expectations for an intuitive and friendly HMI are cultivated by
the likes of, as mentioned, Google, Microsoft, Apple, Facebook
and many others, i.e. — the expanded possibilities of an app
should not necessitate a greater difficulty of use.
A Modern Gear Form Grinding Machine Has Many

Functions and Features
Let’s look at the example of a contemporary gear form grind-
Figure 1 M. Maag & E. Buchter patent for tightening bands of rolls ing machine that has a lot going on (Fig. 2). While gear grinding
simultaneously and equally, 1920.

Figure 2 Example of contemporary gear form grinding machine with a lot going on.
is the prime function of the machine, it is only one of its many

functions; other supporting functions include:
• On-board dressing of the grinding wheel
• On-board gear inspection and evaluation of inspection results
• Intelligence to make automatic or manual process/setup
adjustments based upon on-board inspection results.
All these prime and supporting functions have many data
entry fields for the operator to control and to fine tune to ensure
proper functionality.
Grinding gears is the main machine function. This function
relies on numerous data points defining the basic gear geom-
etry (Fig. 3); profile and lead modifications; the gear axial and
angular orientations in relation to the grinding wheel; grind-
ing method; feed and speed rates; number of passes; and many
more data points for the “control knobs” to properly complete Figure 3 Grinding utilizes numerous data points in defining basic gear
the task. geometry.
Typical features and flexibilities of the form grinding function
are: root geometry (Fig. 4):
• Grinding spur and helical gears • Straight or parabolic tip relief
• Usage of dressable or non-dressable wheels • Profile crowning
• Possibility of grinding two or a single flank at a time • Point-by-point profile corrections
• Profile and lead modifications • SAP or TIF (start of active profile or true involute form)
• Root/fillet radius
On-board dressing is one of the supporting functions. In
addition to the basic gear geometry, this function relies on Figure 5 depicts an example of the dresser geometry, as this is
the information about the profile modifications, dressing tool another critical set of information required for generating preci-
geometry, dressing conditions, and the fine tuning fields to sion dressing passes.
develop optimized dresser passes that minimize dressing time. Figure 6 depicts a typical geometry definition of a purchased
Examples of data entry for typical profile modifications and grinding wheel; it is a third set of the information needed for

technical
the wheel dressing process. Dressing con-

ditions (Fig. 7) are the fourth set of the
information needed for the wheel dress-
ing process.
Based on these four sets of data, the
dressing passes are generated. Also, some
advanced on-board dressing system may
include a capability for optimizing the
dressing pass travel for maximum effi-
ciency. Figure 8 represents a visual veri-
fication of an optimized, initial dressing
pass. The operator has a chance to visu-
ally review the optimized dresser passes
in order to reduce a chance of a crash
and to minimize (or eliminate) the num-
ber of wasted passes.
On-board inspection. Today’s not
only large, but also medium-size gear
grinding machines are increasingly
being manufactured with an on-board
inspection capability. Here are some of
the on-board inspection features and
capabilities:
• Inspection and evaluation of profile,
lead, index, tooth thickness, OD and
root diameter
• Automatic tooth finder and stock
division
• AGMA/ISO/DIN standard determina-
tion and tolerance calculation
• Probe calibration without interrupting
part setup Figure 4 Various profile modifications and other details.
Integrating inspection with setup

adjustments. While more grinding machines have features to The Prominence of Human Machine Interface (HMI)
help operators determine the necessary adjustments based on With so many different capabilities, functions, features, and
external inspection, the on-board inspection provides a more fine tuning “knobs,” how does the operator “connect the dots”?
fertile soil for automating the setup adjustments for profile, lead How does the operator achieve a situational awareness (SA),
and tooth size. i.e. — what do I do next? How do operators maintain their san-
ity? What makes the machines easy to use?
The trends in gear manufacturing (for making the machine
easier to use) are no different than what is happening in com-
puting elsewhere. Computer functionality is becoming more
and more accessible to people without an advanced computer
education. Our smart phones (that are basically pocket com-
puters with many software features) today are so much more
complex and more capable than earlier computers. Yet, thanks
to more intuitive and friendlier user interfaces (UIs), billions
of people easily navigate smart phones today. In contrast, only
a few elite professionals were able to navigate earlier computers
that were significantly less capable and less powerful.
HMI or UI are just different names for the same concept,
i.e. — means for a human/user to interact and control a machine
or a computerized process. HMI bears the prime responsibility
for the operator experience and for making the functionality of
the machine explicable.
Figure 5 Example of dresser geometry — another critical set of

information required for generating precision dressing passes.

Typical Wheel (Norton)
Figure 6 Typical geometry definition of purchased grinding wheel — the third set of information needed for
wheel dressing process.
How to Design an Intuitive HMI/UI indicate an action is taking place, and whether it was either
Everett McKay, the author of “UI is Communication: How to successful or unsuccessful.
• Forgiveness. If users make a mistake, they need the ability to
Design Intuitive, User-Centered Interfaces by Focusing on Effective
fix or undo the action with ease.
Communication,” says that an intuitive interface should include • Explorability. Users can navigate throughout the UI without fear
an appropriate combination of the following: of penalty or unintended consequences, without getting lost.
• Affordance. The UI provides visual clues that indicate what it
is going to do. Users don’t have to experiment or deduce the Data Entry
interaction. Affordances are based on real-world experiences Data entry is one of the first things the operator needs to do
or standard UI conventions. when starting a new grinding project. A gear grinding machine
• Expectation. The UI delivers expected and predictable results with on-board dressing, on-board inspection, and built-in intel-
with no surprises. User expectations are based on labels, real-
ligence for setup corrections requires a cornucopia of data,
world experiences, or standard UI conventions.
• Efficiency. The UI enables users to perform actions with mini- e.g. — basic gear data; modification data; dressing data; inspec-
mal effort. If the intention is clear, the UI delivers the expected tion data; grinding data; and so on. Below are some of the data
results the first time so that users don’t have to repeat the entry principles that would make it easier and more intuitive for
action (perhaps with variations) to get what they want. the operator.
• Responsiveness. The UI gives clear, immediate feedback to • Minimum data entry. While every grinding project requires
Figure 7 Dressing conditions are the fourth set of information needed for
wheel dressing process. Figure 8 Visual verification of an optimized, initial dressing pass.

technical
hundreds of gear geometry and process data entry fields, there
are probably a dozen that “must” be provided by the operator.
For example, only the basic gear geometry data is required to be
entered in order to start a “plain vanilla” gear tooth grinding.
• Defaults. Availability of friendly defaults for all additional gear
geometry fields can dramatically speed up the data entry and
the entire setup process. However, the user is always in charge
and should be able to update any defaults that are calculated
and displayed.
• User-centered. The data entry interface should satisfy different
traditions for the geometry specs, standards, and other com-
pany-specific preferences for gear specs; for example, angle vs.
length of roll, or diameter, tooth thickness vs. span or DOP,
and metric/inch switchable at any time.
• Forgiveness. Automatic reconciling of any interdependent
fields (e.g. decimal degrees vs. min.; and sec., tooth thickness
vs. DOP and span; length of roll vs. angle and diameter, etc.)
The user should be able to see all calculated references, such
as base circle and lead, that were not entered but were critical
characteristics for proper functionality.
Figure 9 Gear teeth with profile modifications. Figure 3 shows an example of the minimum basic gear data
entry; there are only seven data entry fields. All other gear geom-
etry characteristics — with the exception of modifications and
root radius — can be derived from the basic gear data. An operator
should not have to update additional data entry fields, unless the
profile (Fig. 4) or lead modifications (Figs. 11–12) are required.
Visual Gear Data Verification

Visual data verification transforms the numerical data entered
into a scaled pictorial gear representation, thus delivering an
extra level of confidence and allowing the operator to quickly
detect mistakes and typos. Figures 9 and 10 depict examples of
gear teeth with and without profile modifications respectively.
Normal (and transverse in case of helical gears) representa-
tions of the grinding wheel geometry can be superimposed and
viewed on both figures.
Figure 10 Gear teeth without profile modifications.
Figure 11 Symmetric lead modification.

Figure 12 Asymmetric lead modification.
Some Principles of a Good Graphic Design

Graphics are very powerful tools for brief and clear communi-
cation. It is not uncommon for a gear grinding (or other gear
manufacturing) machine to have an HMI that utilizes graphi-
cal communication for the data entry fields. Paul Gruhn’s Good
Graphic Design Concepts/Visual Clues lists some principles of a
good graphic design.
• Grouping: related items are kept together (e.g., all symmetric
lead modifications)
• Contrast: things that are different should look different
• Alignment: every element has some visual connection
• Proximity: things that belong together are placed together
• Repetition: repeat visual elements
Figures 11 and 12 are examples of applications of these prin-
ciples for designing data entry pages for symmetric and asym-
metric lead modifications. Graphics provide visual explanation
for achieving symmetric lead modifications by adding delta
X-axis (center distance) travel in relation to Z axis (axial travel).
Asymmetric lead modifications are achieved by adding delta
C-axis travel (table rotation) in relation to Z (axial travel).
On-Board Gear Inspection

A contemporary gear grinding machine can have an on-board
inspection with a plethora of inspection and evaluation capa-
bilities. Figure 13 depicts a scanning probe installed on a form
gear grinding machine. Every inspected feature requires numer-
ous data entry fields that define the inspection and evaluation Figure 13 Scanning probe installed on a form gear grinding machine.
parameters. However, a friendly and an intuitive HMI can have
the intelligence to default most, if not all, of the data inspection
requirements based on the basic gear data. Of course the opera-
tor should be able to review all defaults and update them, if
desired. Below is an incomplete list of a typical on-board inspec-
tion and evaluation capabilities on a gear grinding (or cutting)
machine.

technical
Figure 14 Example of profile inspection and evaluation.
Figure 15 Profile slope setup adjustment in two steps: symmetric and asymmetric.

Figure 16 Lead setup adjustments are conceptually similar to the profile. Figure 17 Tree project structure (without the
right pane) with expanded notes.
On-board gear inspection and evaluation features: One of the most helpful outcomes of the on-board gear
• Profile: total/slope/form/modifications inspection and evaluation is that the system can use the inspec-
• Lead: total/slope/form/modifications tion results to determine all the necessary setup adjustments.
• Index: pitch/spacing/runout This opens up a possibility for either automated or manual setup
• Tooth thickness/DOP/span adjustments of profile, lead, and tooth thickness features.
• Tip and root diameters • One way to make profile slope setup adjustments is to break it
• AGMA/DIN/ISO down into two steps: symmetric and asymmetric adjustments
• Tolerance band/K-chart (Fig. 15). The asymmetric adjustment is achieved by shifting
Additional on-board inspection and evaluation features: the tangential axis (Y-axis) and the symmetric by adjusting
• Auto average stock divisions the center distance (X-axis) between the gear and the dress-
• Axes alignment mapping ing wheel. This can be accomplished in an automatic mode or
• Automated setup adjustments — MTB setup assistant semi-automatic mode when the operator would be selecting
(Yes/No) for including the adjustments.
A modern on-board inspection feature includes most, if not • Lead setup adjustments are conceptually similar to the pro-
all, the inspection and evaluation capabilities of a traditional file (Fig. 16); it is typically broken down into two steps: sym-
gear measuring center. An example of the profile inspection and metric and asymmetric. The asymmetric adjustment (helix)
evaluation is depicted in Figure 14. is achieved by refining the synchronization of table rotation
(C-axis) and axial travel (Z-axis). The symmetric adjustment
Setup Adjustments (taper) is achieved by refining the synchronization of X and
One particularly exciting HMI feature is built-in intelligence for Z axes. The lead crown correction can be combined with
setup corrections. symmetric and asymmetric corrections. Based on the crown

technical
inspection results, the X-axis

and Z-axis synchronization
can be further refined. Figure 18 Example of profile inspection details via project tree profile inspection node.
Situational Awareness or
Navigating the Gear Grinding Project explicable and intuitive. With friendlier and more intuitive
An intuitive navigation through the gear grinding project is a HMIs that have default features, minimum data entry require-
very important facet of the HMI. A familiar project tree struc- ment, visual verification, and easier navigation, users are now
ture (used in a wide variety of computer applications) enables empowered with both a more pleasant experience and a setup
the user to easily move through many data screens. A project time reduction.
tree structure also provides consistent means for viewing and The author would like to express his gratitude to John Waxler
editing every single detail on the right pane of the project while for his assistance in preparing the supporting graphics and for con-
seeing the “big picture” of the entire project on the left pane. verting the math models into computer codes.
Grinding project comprises:
• Grinding wheel References:
• Diamond/dressing wheel 1. Gruhn, P., P.E. “Human Machine Interface (HMI),” 2011. www.kirp.chtf.stuba.
• Gear sk/moodle/pluginfile.php/61474/mod_resource/content/2/hmi_rules.pdf.
2. Levey, S. GUI (Graphical User Interface). www.britannica.com/technology/
• Grinding process graphical-user-interface.
• Dressing process 3. McKay, E. “UI is Communication: How to Design Intuitive, User-Centered
• Selected cycles (orientation — aligning of the grinding wheel Interfaces by Focusing on Effective Communication,” Everett McKay. www.
with gear tooth, grinding, inspection, adjustments) uxdesignedge.com/2010/06/intuitive-ui-what-the-heck-is-it.
4. Isaacson, W. “The Innovators: How a Group of Hackers, Geniuses, and Geeks
• Results of inspection Created the Digital Revolution,” 2014.
• Setup adjustments recommendations 5. MAMBU: www.mambu.com/en/intuitive-interface-28. “It is better to adapt
the technology to the user than force the user to adapt to the technol-
Grinding project tree can include familiar navigational fea- ogy.” — Larry Marine.
tures such as: 6. UXDesignEdge Blog, Everet McKay. “(An HMI) is intuitive when users under-
stand its behavior and effect without use of reason, experimentation.” Wiki.
• Collapsing/expanding nodes in the project tree
• Adding/removing/sequencing grinding process items (orien-
tation, dressing, grinding, inspection)
A tree project structure (without the right pane) with some
expanded notes is shown (Fig. 17). The operator may collapse Yefim Kotlyar is the application engineering
or expand each node at will. Figure 18 depicts an example of the manager at Machine Tool Builders (MTB),
responsible for the development of new gear
profile inspection details as viewed by clicking on the project manufacturing and gear metrology technologies. His
tree “profile inspection” node. broad experience in the art of gearing includes the
development of various gear cutting technologies,
Conclusion analytical inspection and evaluation technologies
for gears and hobs, as well as gear system design
Once again, HMI bears the prime responsibility for the opera- and validation. Kotlyar has served on a number of AGMA technical
tor experience and for making the functionality of the machine committees, and he has authored numerous articles on gearing.

technical
Standard Samples for

Grinder Burn Etch Testing
Jonathan R. Crow and Michael A. Pershing
Introduction
Surface temper etch inspection (“acid etch” testing) for thermal
damage as a result of hard finishing (typically, grinding) opera-
tions is the most prevalent inspection method in gear manufac-
turing. The acid etch method relies on contrast in color, result-
ing from nitric acid severity of attack on thermally affected areas
vs. those areas that are not thermally affected. There are known
issues with maintaining proper nitric acid baths, HCl baths,
wash baths, and rinse baths. Assurance that an acid etch system
and method is working correctly requires a standard sample.
This paper discusses a unique method of producing a sample
that has a very consistent amount of thermal damage. Multiple
degrees of burn are applied to the sample to ensure that the etch
inspection can detect all levels of potential burn on the piece
parts. The sample can then be reliably used to test an acid etch
system and method to ensure the proper amount of contrast for
threshold levels of thermal damage. The developed sample, with Figure 1 Series of tanks for acid etching in a gear manufacturing
facility.
standardized burns, may be processed through the etch tanks
at frequent intervals (or even simultaneously with piece parts)
to ensure the etch system is able to detect any burn that may be
present on the actual piece parts. The method of producing the
sample is described here, as are methods of quality control using
the standard.
Hardened gears — subsequently hard finished (typically via
hard grinding) — can be subjected to thermal damage known
as “grinder burn.” This undesirable thermal damage occurs if
hard grinding variables are not carefully controlled. The thermal
damage resulting from grinder burn affects near-surface metal-
lurgical properties and can result in reduced gear life or even
premature failures. The harmful effects depend on the degree
of thermal damage present and can include reduced hardness,
increased hardness, harmful change in residual stress state, and
even cracking in more severe cases. Detection of this burn is
critical in any quality control plan for hard ground gears.
Although various methods are utilized to detect grinding burn,
many gear manufacturers continue to utilize one of several variet-
ies of surface temper etch inspection methods (herein called “acid
etching”). Acid etching has been utilized for many years with suc-
cessful implementation in many industries that utilize hard grind-
ing. Other NDE methods are also utilized, such as Barkhausen
noise, which have been beneficial but also difficult to implement
economically and without confident correlation of results. For
this reason acid etching is the most common method.
Several international standards exist for grind burn acid etch-
ing (Refs. 1–2). Exact processes vary, but all generally use some
combination of pre-cleaners, etching acids, rinses, and rust pre- Figure 2 Example of burned gear after going through the acid etch series
ventive steps (Fig. 1) to create a detectable visual contrast on any of tanks; dark areas show “temper-back,” with some visible
cracking.
Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Fifth Floor, Alexandria, VA 22314-1587. Statements
presented in this paper are those of the author(s) and may not represent the position or opinion of the American Gear Manufacturers Association.

burned areas of the ground surface (Fig. 2). Regardless of the verification of etch process performance; but creation of these
method used, the detection of damage is visual — and therefore samples is out of scope of these documents, therefore they lack
extremely dependent on careful control of the etching processing any detail about how to create them. While creating deliberate
variables to achieve an acceptable result. After burned parts are grind burn on a test sample is certainly possible with a grind-
acid etched, differing degrees of grinder burn are visually discern- ing wheel, the repeatability of any type of such a process is likely
able and differ in appearance and therefore simultaneously pro- to be low. Replication of a consistent level of thermal damage is
vide guidance on both the presence and severity of burn. In order desirable for sample distribution among various facilities in an
to assure that the acid etching procedure and system is working organization, for example. Creating varying levels of thermal
well, a standardization sample is desired to ensure adequate con- damage on a prepared test sample is possible in a repeatable
trols over all of the variables encountered in acid etching. fashion and is the focus of this paper.
“Grinder burn” is a blanket term that encompasses varying
degrees of thermal damage, and etching is used to indicate both Discussion and Future Work
the presence and severity of any burn present. After etching, an Ideally, a single test sample could be created that would show
undamaged part will be a uniform light gray color. Areas heated different levels of tempering or thermal effect. In order to emu-
enough to cause excessive tempering will etch darker than this late the thermal effects of grinding damage, a laser was used to
uniform light gray and will appear between a darker shade of create a specimen with exact and differing levels of tempering or
gray or even black, depending on severity of temperature expo- heat throughout one specimen. Laser heat treatment of sample
sure. This type of damage is commonly called “over-tempering,” plates, consisting of similar material and heat treatment as the
“temper-back,” or simply “tempering.” The most severe type of subject parts, is the proposed solution to the desire for a single
burn occurs when the thermal exposure due to grinding dam- standard test piece. Laser heat treating is an attractive option
age exceeds the material’s austenitizing temperature, and is because of its ability to create multiple levels of thermal damage
commonly called “re-hardening.” Re-hardened areas etch white on the same part with the same process in a single part setup.
against the gray background and are typically surrounded by an Additionally, the heat input is controllable over a range of heat
intermediate temperature exposure area, etching black or gray inputs. Using this method, a single sample may be thermally
(temper-back). A burned gear could therefore have varying mix- exposed over a range of temperatures, emulating varying levels
tures of black, dark gray, light gray, and even white areas after of grinder burn within the same part. Of particular usefulness,
etching, depending on the severity of burn present. For visual this process may be repeated on multiple samples, creating mul-
detection, any burn must exhibit sufficient contrast against this tiple ‘standardization’ samples that may be used in differing acid
palette of a uniform gray. For any etching process, developing etching processes. Such samples could even be run at the same
this contrast between damaged and undamaged areas is of para- time as the parts being analyzed, thus providing a record of
mount importance. acceptable etching performance.
Since the sample was developed in conjunction with carbu-
Background rized and hardened gear manufacturing, the standardization
There are many variables to control in an acid etch process in sample was similarly carburized and hardened with a similar
order to properly detect grinder burn. Typically, control of the material. The same standardization approach would work with
acid etching process is accomplished through careful control gears hardened by various other means, provided the test sam-
over all measureable process inputs, i.e. — immersion time, ples were manufactured from a similar material and heat treat
bath temperatures, bath concentrations and many others. Loss combination as the audited parts.
of control of any of these variables can create false-positive or Figure 3 is a simple drawing of the proposed sample. This plate
false-negative burn detections — depending on the nature of is first carburized and hardened to an effective case of approxi-
the error — causing unnecessary rework, scrap, or even cus- mately 3 mm and a good surface carbon plateau of 0.8–0.9%
tomer quality excursions. Setting of control limits for each of C. The plates are then very carefully surface ground to remove
these variables is typically based on experience and past prac- approximately 100 microns of material. This minimum stock
tice, which creates the highest possible visual contrast, balanced removal is important to ensure removal of the shallow layer of
with the minimized part damage and material removal from non-martensitic transformation products (NMTP) from the car-
the parts. Establishing control ranges for these various process burized case that would otherwise interfere with accurate visual
inputs is difficult. In fact, limits may even be established that are inspection after etching (Fig. 4). During grinding, parts were
more demanding than the process requires, simply in an effort repeatedly etched to ensure no grinding burn was occurring and
to ensure a semblance of process control. Further, there are sev- the surface grind process was in control. Parts were not etched
eral important variables that are much more difficult to quantify after the final grinding pass to ensure a consistent surface finish
(part cleanliness and bath cleanliness, for example) that are not and reflectance necessary for subsequent laser heat treating.
easily measured or quantified in a production environment. The Laser heat treating was then utilized to create at least three dif-
sample described herein bypasses these limitations of conven- ferent degrees of burn damage — complete re-hardening, heavy
tional process controls and presents a known burn to the pro- tempering, and light tempering, with intermediate levels applied
cess to ultimately test the level of detectability produced by the as space allowed on the surface of the sample (Fig. 5). Once the
entire etching process. cycle was established, it was easily replicated to create many
Multiple standards (ISO 14014 and AMS 2649) (Refs. 1–2) identical samples. Both sides of a given plate may be laser heat
refer to the need of the creation of pre-burned samples to aid in treated, providing two surfaces for inspection if desired. There

technical
are different ways to make the samples, in terms of the laser heat
treat pattern. The samples may be sectioned into smaller pieces
as desired. Various lasers and settings could be utilized to pro-
duce the sample. For this work, a 4,000W direct diode laser was
utilized (880 nm wavelength, continuous wave).
Once a consistent set of samples has been created, it is ready
to be utilized as a part of the quality control around the acid
etch process. A sample can be processed in a given acid tank as
an audit of etching performance. The sample may be run peri-
odically (i.e., 1×/shift, 1×/4 hours, etc.) or even run side-by-side
with especially critical piece parts. Samples may also be cleaned
and re-used multiple times. Re-use frequency is dependent on
Figure 3 Drawing showing dimensions of the round plate that is
carburized, hardened, and lightly ground and then laser heat etch cycle specifics (concentration, immersion time), but re-use
treated. of samples up to 20 times has been observed. While cleaning via
abrasive pad between etching runs was used for these studies,
any cleaning method that minimizes stock removal and returns
the part to a shiny, pre-etching appearance is acceptable. After
too many etching cycles, the more aggressive acid attack in the
burned areas eventually creates observable pitting on the sur-
face of the sample, at which point it should be discarded and
replaced. Pictures may also be kept of etching performance of
the test sample from each etching cycle as an additional record
of process performance.
Both Type I errors (α-Risk, Producer Risk) and Type II errors
(β-risk, Consumer Risk) can occur with grind burn etching
processes if variables are not closely controlled. The test sam-
ples can help to avoid either type of error but are particularly
effective in avoiding Type II errors. In a scenario without use
of the sample, the etch tank could be completely ineffective in
detecting burn, and be unknown to the inspector. In this case,
the inspector could unknowingly release burned parts to a cus-
Figure 4 Non-martensitic transformation products at the surface of tomer. Using the described ‘standard’ samples now allows the
the plate after carburize and harden. Removal by grinding
is necessary to keep steady temper-back color effects. inspector to be sure that the tank performance is adequate to
The grinding must be done carefully so there is no thermal detect the necessary ranges of burn severity.
damage. The samples are also particularly useful to assess potential
changes to the acid etch procedure. Changes to chemical types,
suppliers, or concentrations are sometimes necessary or desired,
and there may be questions about the process remaining effec-
tive or equivalent to the previous procedure. These samples pro-
vide a method for judging the effectiveness and equivalence of
these changes.
Conclusions / Summary
• A standard sample was created to standardize and “master”
the performance of a given etch tank and process.
• The sample ensures that differing levels of thermal damage
can be detected by using laser heat treatment to create areas of
re-hardening, heavy tempering, and light tempering — all on
the same sample piece.
• A single standard sample piece can be reused multiple times.
Figure 5 The standard sample as it appears after a good acid etch. • The sample is effective for use in daily quality control or in
evaluating potential acid etch procedure changes.
References
For Related Articles Search 1. ISO 14014. , 2009, “Acid Etch Testing,” ISO Std. 1596–992, 2009.
2. AMS 2649. “Acid Etch Testing,” AMS Std., 2010.
nital etch

FREE
SUBSCRIPTION
18GTPAGE
RESPONSE REQUIRED
YES I want to receive/continue to receive Gear Technology
Thanks anyway, but I don’t need the world’s best
NO publication on gear engineering and manufacturing.
Name _______________________________________ Job Title _________________________

(please print)
Signature _______________________________________ Date _________________________

(required)
How would you like to receive

Gear Technology? *Your PRIVACY is important to
us. You get to CHOOSE how we
 PRINT version (Verify mailing info below) use your personal information.
 DIGITAL Version (E-mail required) The next e-mail we send you
will have clear instructions.
 BOTH Print AND Digital (E-mail required)
E-mail _______________________________________________*
MAILING INFORMATION
How are you involved with GEARS?
NAME:
 My company MAKES GEARS (20)
JOB TITLE:
 My company BUYS GEARS (22)
COMPANY:
 I DESIGN gears (23)
ADDRESS:
 I am a SUPPLIER to the GEAR INDUSTRY (24)
 Check if this
 OTHER (Please describe) _______________________ is a home
address
What is your company’s principal

CITY:
product or service? ___________________
STATE/Province:
_________________________________________
ZIP/Postal Code:
PHONE:
FAX:
Put your business card

here to make it easier!
Mail to: FAX to 1-847-437-6618

1840 Jarvis Ave., Elk Grove Village, IL 60007 USA or SCAN to: subscribe@geartechnology.com
industry news
AGMA/ABMA
ANNUAL MEETING HIGHLIGHTS
More than 300 executives gathered in late April to connect and engineer, gear engineer-
network with peers at the 2018 AGMA/ABMA Annual Meeting in ing and development.
Naples, Florida. Here are some of the highlights during the event: From there he moved
to American Axle and
Lifetime Achievement Award Manufacturing and then
The American Gear Manufacturers Association (AGMA) pre- to his current position at
sented David Goodfellow, president of Star SU, with the Meritor.
AGMA Lifetime Achievement award. This award is presented “Jack is a great example
to someone who has of what this award repre-
demonstrated dedication sents,” said James Bregi,
and leadership for the chairman of the AGMA
advancement of the gear Board of Directors. “His
industr y and AGMA, dedication to the gear
exemplif ied sup erior industry and leadership
vision and exceptional throughout the years to
knowledge that has been AGMA is something we
shared with colleagues all hope to strive for.”
and achieved admiration Masseth is an active member on the Vehicle Gearing
and respect of peers. Committee, Gear Efficiency Committee, the Gear Accuracy
“David has gone above Committee and the Emerging Technology Committee. Jack
and beyond for the gear was also instrumental in helping AGMA begin the Strategic
industry and has been a Resource Network or SRN. This group has played an important
true leader to all of us in manufacturing,” said James Bregi, part in attracting new leaders to AGMA.
chairman of the AGMA Board of Directors. “He has generously
given his time and resources to help in the advancement of Next Generation Award
AGMA and its members.” The American Gear Manufacturers Association (AGMA) pre-
Goodfellow began his career in gears after serving in the U.S. sented Maeve McGoff, sales and marketing coordinator at
Army and attending Syracuse University. He was eventually Cincinnati Gearing Systems, with the AGMA Next Generation
named president of American Pfauter in 1981. Most notably, award. This award is
Goodfelllow was instrumental in the introduction of the wafer presented to some-
hob concept and the advancement of high-speed gear hobbing one who, while early
while with American Pfauter and Pfauter Maag Cutting Tools. in their career, is an
“David’s name is synonymous with expertise and leader- emerging contributor,
ship in our industry worldwide,” Jeff Lawton of Star Cutter innovator and leader
Company noted in his nomination. “For nearly 50 years, David in the gear industry.
has impacted those around him as a colleague and mentor and A Next Generation
most importantly, as a leader.” award recipient dem-
Goodfellow was part of the visionary leaders in the cre- onstrates hard work
ation of the Gear Expo tradeshow. Additionally, he has been and acts as a role
an ambassador to the international companies assisting in model for others while
the transition of AGMA to becoming a global leader for gear h av i ng a p o s it ive
manufacturers. impact on AGMA.
McGoff has seven
Chairman’s Award ye ars in t he ge ar
The American Gear Manufacturers Association (AGMA) pre- industry and has excelled in bringing a strong online presence
sented Jack Masseth of Meritor, Inc., with the AGMA to her company through re-branding, graphic design and video.
Chairman’s award. This award is presented to a recipient that Her energy and determination to bring innovation to manufac-
has contributed greatly to the gear industry and has gone above turing has been demonstrated through her active role in attend-
and beyond the call of duty to support innovation and advance- ing AGMA events and working to deliver value in modern plat-
ment through AGMA. forms through social media and digital marketing.
Masseth graduated from Rochester Institute of Technology in “Her advertising and promotional methods not only informs
Mechanical Engineering and began his career at The Gleason and delivers value in a factual sense, they are also creative and
Works. After 13 years of applications engineering he moved appealing for a common consumer,” explained Patrick Potter,
to Dana in Fort Wayne, Indiana and work for 14 years as chief director of sales with Cincinnati Gearing Systems. “Maeve has

brought Cincinnati Gearing systems to the forefront of modern
marketing. . .it is easier for CGS to connect to the younger gen-
eration and hopefully close the age gap in the workforce.”
McGoff will be joining AGMA committees and has already pro-
vided many photos for AGMA events and the epicyclic committee.
The American Gear Manufacturers Association (AGMA)
also announced Benjamin Sheen, gear engineering specialist
at Eaton — vehicle group has been awarded the AGMA Next
Generation award.
Sheen has aided the gear industry through innovative solu-
tions and intellectual property generation, increased gear man-
mwgear@midwestgear.net
ufacturing productivity by introducing state-of-the-art pro-
cesses and mentored young engineers at manufacturing plants
and centers for developing the next generation. He was respon-
sible for managing the installation of six robotic lines at Eaton,
which increased their manufacturing productivity.
“Ben has been instrumental to advance gear technology
within Eaton,” Carlos Wink wrote in his nomination. “He is a
role model for Eaton’s global gear team, inspiring others to fol-
low his steps as an innovator and engineering leader.”
Sheen is a member of the AGMA Vehicle Gearing Committee
and has taken five courses with AGMA to earn his Advanced
Gear Engineering Certificate. Sheen has also presented at the
AGMA Fall Technical Meeting where his paper was later pub-
lished in Gear Technology magazine in July 2016.
AGMA Foundation Receives Donation for Scholarship

Award
The American Gear Manufacturers Association (AGMA)
Foundation received a $100,000 donation from Linda and Bipin
Doshi, formerly of Schafer Industries. The announcement to
endow a scholarship award through the AGMA Foundation
was made to members at the 2018 AGMA/ABMA Annual
Meeting in Naples, Florida last week. The $100,000 donation is
the largest single gift ever received in the AGMA Foundation’s
22 year history. The Doshis have been very active leaders
with AGMA and AGMA Foundation Boards for many years.
With this endowment, the AGMA Foundation will annually
grant a, “Linda and Bipin Doshi Scholarship” to a top schol-
arship applicant. The AGMA Foundation annually grants
scholarships to students who are planning in a career in the
gear industry, or in power transmission as it relates to the gear
industry. Technical/Associate level students are eligible for
$2,500 scholarship awards, while Undergraduate and Graduate
students are eligible for $5,000 awards. The first “Linda and
Bipin Doshi Scholarship” will be granted in August 2019.
“This generous gift will make a real difference in the lives
of many students, and will provide the gear industry with a
strong talent pool,” says Cindy Bennett, executive director of
the AGMA Foundation. “The future of the AGMA Foundation
Scholarship program depends upon the generosity of donors
such as Mr. and Mrs. Doshi. The Linda and Bipin Doshi
Scholarship Endowment will grow and perpetuate excellence in
the gear industry for many years to come.” (www.agma.org)

industry news
Klingelnberg
SHOWCASES HIGH-PRODUCTION
GENERATING GRINDING IN GERMANY
From April 18 to 19, 2018, international experts from the auto-

motive industry were inspired by the system supplier’s indus-
try-specific solutions at Klingelnberg’s Ettlingen Oberweier
plant. In keeping with the theme of “High-production gener-
ating grinding in large-scale production — quiet gearing with
Klingelnberg Industry 4.0 solutions,” the main attraction of the
event was the market launch of the Speed Viper2 cylindrical
gear generating grinding machine featuring the dual-spindle
concept. On either side stood additional exhibits from the
Höfler cylindrical gear and Oerlikon bevel gear machine lines,
precision measuring centers from Klingelnberg and innovative
production concepts such as Smart Tooling and Closed Loop.
A winner of the iF-Design Award, the Speed Viper cylin-
drical gear generating grinding machine was developed by
Klingelnberg with a special focus on high-production generat-
ing grinding. The innovative machine concept was presented
to a large audience for the first time at EMO 2017 in Hanover,
Germany. The solution provider took the opportunity of this
two-day workshop to present further innovations to its custom-
ers in a targeted, application-centered setting. The dual-spindle
concept of the Speed Viper² is especially designed to meet the
productivity requirements of the automotive industry and its
suppliers. Whereas the single-spindle machines offer high ver-
satility and short set-up times, the dual-spindle machines are
designed for large-scale production and minimal cycle times.
In a number of interesting live demonstrations, over 100 gear
experts from throughout Europe, Asia and the USA had an
opportunity during the two-day event to design their own
generating grinding process on the single- and dual-spindle
machines on display: Speed Viper 300, Speed Viper 180 and
Speed Viper2 80.

Cylindrical gear production in the Industry 4.0 The Gleason-Pfauter Studen organization has approximately
concept 120 employees and focuses on the design and manufacturing
The innovative production philosophy manifested in the Speed of gear hobbing, gear power skiving and gear profile grinding
Viper establishes a solid basis for quiet gearing in the Industry machines all of which are typically equipped with automa-
4.0 production environment. This is because the Speed Viper tion solutions. Its products are shipped globally to a variety of
works with Klingelnberg precision measuring centers in the industries including automotive, power tools and aerospace, to
fully automatic, corrective Closed Loop. The experts from name a few.
Klingelnberg presented this technology using the P 40 precision The Gleason-Pfauter operation located in Studen has grown
measuring center on display. And Smart Tooling, the digital rapidly in recent years necessitating a move to a larger build-
tool management system from Klingelnberg, ensures outstanding to accommodate its expanding volume of business. The
ing quality management throughout the process, since it pro- new advanced manufacturing facility extends the company’s
vides a precise overview of the tool status at any time — another office space by 30% and machine assembly capacity by almost
key component of the Industry 4.0 concept. 60% compared to the previous premises. The assembly area has
been optimized for effective material flow and the building was
Greater versatility on the shop floor designed with energy efficiency and maintaining a low carbon
In the presentation areas at the Ettlingen plant, workshop par- footprint as high priorities.
ticipants were also able to see for themselves what efficiency Rudolf Moser, general manager of Gleason-Pfauter Studen,
gains can be achieved in gear production thanks to modern said “New technologies, including power skiving, are driving
technology. For example, in addition to the well-known and great interest and business opportunities from our customer
established bevel gear methods for large-scale production, the base. Our success is a credit to our employees. Through their
Oerlikon C 30 bevel gear cutting machine can also be used efforts our business continues to grow each year. Our new fac-
for machining cylindrical gears. As a complete machine tool, tory will create an even better environment to further develop
the Höfler TM 65 likewise surpasses virtually every competi- new products and technologies and continue producing highest
tor when it comes to versatility due to its ability to produce quality machines.” (www.gleason.com)
any type of complex gear bodies from bar stock in a complete
machining process.
Interesting talks in a relaxed atmosphere

Forest City Gear
ADDS DIRECTOR OF SALES
A series of timely talks on interesting technological topics
rounded off the direct impressions participants gained from the Forest City Gear has hired Erik J.
machines on site. Participants also took advantage of the oppor- Spurling as director of sales to
tunity to address specific issues with the gear specialists from oversee the activities of the compa-
Klingelnberg and to discuss application questions in a practical ny’s network of direct and indepen-
setting. (www.klingelnberg.com) dent sales representatives nation-
wide, and to lead sales strategies
Gleason that meet the growing demands of

a wide and diverse customer base
throughout the world’s gear-making
INAUGURATES NEW TECHNOLOGY
AND MANUFACTURING CENTER IN industries.
SWITZERLAND Spurling brings a wealth of
sales and marketing experience and a deep familiarity with
On April 19th, Gleason held a grand opening ceremony for its all facets of inside and outside sales and customer ser-
new facility in Studen, Switzerland. Many important customers vice processes, along with a strong background in manu-
from across the world attended the event which also included facturing. This background, combined with his exten-
product and technology demonstrations. sive sales and marketing leadership skills, made him an
ideal candidate for the new position, says Wendy Young.
“Manufacturing the world’s best gears has always been the com-
pany’s focus — Erik will help to elevate our sales efforts to that
same level,” says Young. “Our sales force, and the customers
they serve, will benefit greatly from new strategies and meth-
odologies that make the sales process faster and more efficient.”
(forestcitygear.com)

ad index
6K Products – Page 31 Nachi – Page 43
6kproducts.com www.nachiamerica.com
B&R Machine and Gear Corp. – Page 12 Nordex Inc. – Page 32
www.brgear.com www.nordex.com
Beyta Gear Service – Page 62 Norton/Saint-Gobain – Page 19
PUTTING www.beytagear.com nortonsga.us/xtrimiumgt
A LIFETIME Bourn & Koch – Page 3 Oelheld US Inc. – Page 33
www.bourn-koch.com www.oelheld.com
OF The Broach Masters & Universal Gear – Page 27 Orris Drive Inc. – Pages 33, 60
www.broachmasters.com b2b.worldtrade.org.tw/16697150
GEAR Circle Gear – Page 32 Riverside Spline and Gear – Page 31
DESIGN www.circlegear.com
DTR Corp. – Page 16
www.splineandgear.com
Schnyder S.A. – Page 59
EXPERIENCE www.dragon.co.kr www.schnyder.com
DVS Group – Page 13 Shangchi Group – Page 60
www.dvs-technology.com www.jssc.com.cn
TO WORK FOR YOU
Forest City Gear – Page 29 SMT – Page 25
www.forestcitygear.com smartmt.com/masta-energy
• Reverse engineering • Design reviews Gear Research Institute – Page 31 Star SU LLC – IFC-Page 1, Page 32
• Gearbox upgrades • Bid evaluations gearresearch.org www.star-su.com
• Custom gearbox design • Tooling design
• Specification development • Customized gear training Gleason Corporation – Pages 4, 15 United Tool Supply – Page 4
• Project management • Equipment evaluation
www.gleason.com unite-a-matic.com
• Vendor qualification • Custom machine design IMTS – Page 53 Wenzel America – Page 11
www.imts.com www.wenzelamerica.com
Charles D. Schultz Index Technologies – Page 31
chuck@beytagear.com www.gregallenco.com
Ipsen International – Inside Back Cover
[630] 209-1652 www.ipsenusa.com
Kapp Niles Metrology – Page 24
www.gearinspection.com
www.beytagear.com
Kapp Technologies – Page 17
www.kapp-usa.com
KissSoft USA, LLC – Page 4
www.kisssoft.com
Unlocking
Klingelnberg – Outside Back Cover
www.klingelnberg.com
the Vault
Liebherr – Page 5
www.liebherr.com
Luren Precision – Page 18
lurenusa.com
Machine Tool Builders – Page 7
Machinetooldbuilders.com
Mcinnes Rolled Rings – Page 35
We’ve optimized more than 30 years of www.mcinnesrolledrings.com
gear manufacturing articles with our Midwest Gear & Tool – Page 59
enhanced search engine at midwestgear@sbcglobal.net
Mitsubishi Heavy Industries America – Page 8
www.mitsubishigearcenter.com
www.
geartechnology
.com.
www.geartechnology.com/issues/

calendar
June 12–15—HxGN Live 2018 Las Vegas, Nevada. HxGN vations emerging in the field. The CMS Executive Board peer
LIVE is for manufacturers seeking to learn more about process reviews all technical papers and publishes top selections in its
automation, closed-loop manufacturing, and connecting CAE, prestigious, high-impact Journal of the CMSC. For more infor-
CAD, CAM and metrology technology via the digital thread. The mation, visit www.cmsc.org.
conference stages more than 120,000 sq. ft. of Hexagon technol-
ogies, nearly 500 sessions and 60+ exhibiting sponsors. The Zone July 30-August 2–CAR Management Briefing
technology expo features the digital thread at work as a com- Seminars Grand Traverse Resort, Traverse City, Michigan.
mon communication framework with feedback loops that embed Initiated by the University of Michigan in 1965, the first Center
continuous improvement into the product lifecycle. HxGN for Automotive Research Management Briefing Seminars (CAR
SMART Quality, Hexagon’s online quality data and measurement MBS) hosted only 30 people. When the industry was at its high-
resource management platform, is one of the prime tech highest number of employment, the event grew to attract more
lights in The Zone. The innovative solution delivers informa- than 1,400 attendees annually from more than 35 states and
tion automation to quality management, so manufacturers and 15 countries−representing industry, academia, media and the
quality control professionals can shape smarter workflows and government. CAR MBS leads the industry in providing a con-
actively improve efficiency and productivity. For more informa- text for auto industry stakeholders to discuss critical issues and
tion, visit hexagonMI.com. emerging trends while fostering new industry relationships in
daily networking sessions. Seminars include targeted sessions on
June 17–20—PowderMet 2018 San Antonio, Texas. manufacturing strategy, vehicle lightweighting, connected and
PowderMet2018 is the International Conference on Powder automated vehicles, advanced powertrain, supply chain, sales
Metallurgy & Particulate Materials. The conference will feature forecasting, purchasing, talent and designing for technology. For
over 200 worldwide PM industry experts presenting on PM, par- more information, visit www.cargroup.org.
ticulate materials, and metal additive manufacturing. The event
includes extended exhibit hall hours, student poster sessions, August 7-9–Ipsen U Cherry Valley, Illinois. Throughout
evening networking events and the return of the co-located pro- the course, attendees are able to learn about an extensive range
gram AMPM2018, featuring worldwide industry experts present- of topics - from an introduction to vacuum and atmosphere
ing on the latest developments in the fast-growing field of metal furnaces to heat treating, furnace controls, subsystems, main-
additive manufacturing. AMPM2018 also hosts a 100+ exhibitor tenance and more. They will also be able to view the different
trade show in conjunction with PowderMet2018. “Metal AM is furnace components firsthand while learning how they affect
a natural fit for MPIF as we have supported the PM industry for other parts of the furnace and/or specific processes, take part in
nearly 75 years. We’re excited to offer an expanded AMPM con- one-on-one discussions with Ipsen experts, participate in a leak
ference that allows for more time for the transfer of technology, detection demonstration, and tour Ipsen’s facility. The Ipsen U
and to expose the metal AM sector to the greater PM industry classroom features comfortable seating for up to 36 attendees, as
through access to both AMPM and PowderMet conferences,” said well as integrated technology with a large smartboard and two
James P. Adams, executive director/CEO of the MPIF. For more additional monitors for interactive presentations and demon-
information, visit AMPM2018.org and PowderMet2018.org. strations. Register today for an upcoming 2018 Ipsen U course at
www.IpsenUSA.com/IpsenU.
June 27–28—Dritev 2018 Bonn, Germany. Increased
CO2 discussions, sustainable mobility and electrified drives: The August 6-8–SAE Fundamentals of Modern Vehicle
automotive transmission world is changing. Why the under- Transmissions Seminar Troy, Michigan. Starting with a
standing of the transmission changes, how it is to be understood look at the transmission’s primary function — to couple the
as part of the overall powertrain and why cross-component engine to the driveline and provide torque ratios between the
know-how becomes more and more important are the subjects two — this updated and expanded seminar covers the latest
of the Dritev in Bonn. Attendees can expect more than 1,500 transmission systems designed to achieve the most efficient
developers, around 100 international exhibitors and 80 special- engine operation. Current designs, the components and sub-
ist lectures on one of the world’s largest networking platforms systems used, their functional modes, how they operate, and the
for powertrain and transmission development. Thus, Dritev inter-relationships will be discussed. For more information, visit
seamlessly connects to the long-standing tradition of the VDI www.sae.org/learn/content/99018/.
Congress “Drivetrain for Vehicles.” At the heart of the event is its
selected technical program, which reflects the current challenges
September 10-15–IMTS 2018 Chicago, Illinois. More
than 115,000 industrial decision-makers attend the International
and developments in the transmission world. The program
Manufacturing Technology Show to get ideas and find answers
includes subjects such as the transmission topology for electri-
to their manufacturing problems. They will see new technol-
fied powertrains and current concepts for automatic transmis-
ogy demonstrated in areas like aerospace, automotive, machine
sions and e-axes. In these, the individual components motor,
shop, medical and power generation. The IMTS Conference
axle and gear are integrated in one element. For more informa-
Program will focus on six topics in 2018 including Process
tion, visit www.dritev.com.
Innovations, Alternative Manufacturing, Plant Operations,
July 23–27—2018 Coordinate Metrology Society Automation, Quality and Industry 4.0/IIoT. Co-located shows
Conference Reno, Nevada. Designed to empower a rapidly include Hannover Messe USA: Integrated Automation, Motion &
evolving profession, the CMSC attracts metrology practitioners, Drives, Surface Technology, ComVac and Industrial Supply. The
quality control managers, manufacturing executives, scientists, Smartforce Student Summit will once again promote student
students and educators. Attendees will find enriching, informa- and educator attendance and other familiar attractions such
tive opportunities to learn about technology achievements, net- as AMT's Emerging Technology Center will highlight the latest
work with high-level master users, and get an overall picture of manufacturing technologies. For more information, visit www.
the state of the metrology industry. The conference is renowned imts.com.
for its original, expert-level technical papers and presentations
covering the successful use of measurement and inspection
technologies, industry best practices, new applications and inno-

addendum
Setting a Hundred-Year Standard

Remembering Panhard and Levassor, the company
that invented the first manual transmission.
Alex Cannella, Associate Editor
20th century French automobile to Bordeaux and back, before the hobby
company Panhard and Levassor ultimately claimed his life in 1897 in a fatal
were always unconventional. racing accident. Panhard, the other mind
Sometimes, their deviations from the norm of the pair, would pass on, as well, a decade
didn’t quite pan out. For example, one car, later.
the Panhard and Levassor Dynamic, fea- The company’s innovations didn’t stop
tured the driver seat in the middle of the car, after its two founders had passed, however.
with passengers on either side, for a few years Most notably, they eventually developed the
before the design was scrapped as awkward and “Panhard rod,” an early suspension rod that you
impractical. can still find on some cars today.
But while Panhard and Levassor’s innovations But here again, Panhard and Levassor the com-
sometimes ended in a few evolutionary dead ends, pany continued to put out less well-known innova-
some also resulted in a lot of the automotive industry’s first big tions for transmission systems. It was never anything huge or
steps that are still standard practice today. flashy, but fundamental steps forward towards what we com-
They were the first to start mounting the engine on the front monly recognize today as a modern transmission. Enclosed
of the car. Before the turn of the 20th century, when automo- gearboxes in 1895. Quadrant changing four-speed transmis-
biles were more still mostly motor buggies, the engine was often sions in 1903. Gated manual shifts in 1910. The list goes on,
mounted behind the driver’s seat. Levassor, the designer of the and certainly isn’t limited to just transmission technology.
duo the company was named after, had been frustrated by previ- After WWII, Levassor’s name was eventually dropped from
ous, unsuccessful automotive designs that followed in the com- the company title, and Panhard continued making cars until
mon rear-engine tradition of the day. So instead, he mounted a 1967. The company’s glory days as a trendsetter well behind
Daimler-patented 1.2 liter V-twin engine to the front of the car it, it was absorbed by Citroën and has been bouncing around
and connected it to a rear-wheel drive to work, a setup known as since until it most recently ended up in the hands of Renault
the Système Panhard. Even if you don’t know it by name, you’re Trucks Defense, part of the Volvo Group.
no doubt familiar with it. After all, a lot of modern cars have Ironically, the trends the company set have outlasted the
been built on its basic principles. company itself, and will continue to do so long into the future.
Panhard and Levassor’s Système Panhard might be the com- But that’s no reason to forget the names of both the company
pany’s most well-known concept, remembered for the many and the inventors that created the foundation for the modern
firsts it brought to automobile design that have become ubiq- automobile: Panhard and Levassor.
uitous today. But the Système Panhard also contained a world
first that is of particular interest to us gear folk.
Levassor replaced the then-traditional belt drives
with the world’s first ever manual transmission
and clutch on an automobile.
It was just a simple three-speed sliding gear trans-
mission that could never hold a candle to anything
on the market today. But the Système Panhard’s
transmission was the dominant design up until
1928, when Cadillac innovated upon it with the
synchromesh transmission, and conceptually, it
remains the embryonic foundation for many of the
basic principles for most transmissions we build
today.
Within a decade, the Système Panhard had been
adopted by most major car manufacturers, includ-
ing Daimler themselves, as well as their main
competitor at the time, Benz. Levassor himself
went on to popularize his system’s design by driv-
ing his own cars on several cross country races,
most notably winning a 730-mile race from Paris

Achieving Increased Profits and Response Times
with Modular Vacuum, Atmosphere Furnaces
“Initially, what appealed to us about this Ipsen

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

go.IpsenUSA.com/Customer-Stories
IpsenUSA.com
WITH CLOSED-LOOP TECHNOLOGY
THE NEW FORCE IN HIGH-PRODUCTIVITY GENERATING GRINDING
POWERED BY HÖFLER!
Now available as
Double-Spindle-Concept
for large series and minimal
non-productive times
The all new SPEED VIPER has been specially designed for smart manufacturing in an Industry 4.0
SUBJECT TO CHANGES.
environment. Needless to say, the high-productivity generatinggrinding machine also meets any
requirements of today’s large-scale production: short set-up times, minimum cycle times, innova-
tive software solutionsand digital process control in the closed-loop system. With this new devel-
opment,a cutting-edge design and an intuitive operating concept, KLINGELNBERG is celebrating a
genuine premiere in the market.
www.speedviper.com
OERLIKON BEVEL GEAR TECHNOLOGY HÖFLER CYLINDRICAL GEAR TECHNOLOGY KLINGELNBERG MEASURING TECHNOLOGY KLINGELNBERG DRIVE TECHNOLOGY
WWW.KLINGELNBERG.COM

Gear Grinding: Software

Uploaded by

Copyright:

Available Formats

Gear Grinding: Software

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Gear Grinding: Software

Uploaded by

Copyright:

Available Formats

JUN

www.geartechnology.com THE JOURNAL OF GEAR MANUFACTURING

This ensures a smaller machine footprint and

54 Standard Samples for Grinder Burn Etch

2 GEAR TECHNOLOGY | June 2018

THE ORIGINAL FELLOWS GEAR SHAPER

TRUE DIMENSION GEAR INSPECTION™

*NO ANNUAL SOFTWARE FEE 58 Industry News

Brian P. Stringer SOFTWARE

www.geartechnology.com THE JOURNAL OF GEAR MANUFACTURING

4 GEAR TECHNOLOGY | June 2018

arTech_KISSsoft_Release2018_89x120_5mm.indd 1 26.04.2018 13:09:42

LC 280 α Gear Hobbing Machine

Liebherr-Gear Technology, Inc.

6 GEAR TECHNOLOGY | June 2018

Visit MachineToolBuilders.com/Burri for details.

An engineer owned company built on complete customer

You’ll want to shout about this

• Grinding speeds faster than

Among many MHI innovations present

Contact Mitsubishi Heavy Industries

Machine Tool Division • Gear Technology Center

Publisher & Editor-in-Chief

June 2018 | GEAR TECHNOLOGY 9

The Junker Group

Doosan Machine Tools America

10 GEAR TECHNOLOGY | June 2018

GEAR CUTTING TOOLS CYLINDRICAL WORM GEARS COMPRESSOR ROTORS

You make it, checks it.

12 GEAR TECHNOLOGY | June 2018

Turning inner diameter

Efficient production of internal and

format for reports is now PDF/A instead of standard PDF.

14 GEAR TECHNOLOGY | June 2018

Every tool is precision-made utilizing high speed steel, premium powder

Learn more about our outstanding quality tools at www.dtrtool.com.

DTR has sales territories available. Call for more information.

16 GEAR TECHNOLOGY | June 2018

KAPP NILES KNe3P

Efficient and easy to use machine concept

pinions, pulleys, rotors, rollers, pistons,

18 GEAR TECHNOLOGY | June 2018

JOIN US AT IMTS 2018 | BOOTH N-237042

Cutting Down on Setup Time

With machining time itself hav-

20 GEAR TECHNOLOGY | June 2018

June 2018 | GEAR TECHNOLOGY 21

Closed loop systems are critical for shaving

22 GEAR TECHNOLOGY | June 2018

June 2018 | GEAR TECHNOLOGY 23

inspection process is outside of the com- revolutionary today, but they’re

KAPP NILES Metrology | Dayton info@kapp-niles.com www.gearinspection.com (937) 660-8182

24 GEAR TECHNOLOGY | June 2018

June 2018 | GEAR TECHNOLOGY 25

Shake, Rattle and Roll

Some truth about gear noise: Meeting Gear Noise

26 GEAR TECHNOLOGY | June 2018

June 2018 | GEAR TECHNOLOGY 27

28 GEAR TECHNOLOGY | June 2018

Figure 3 Chordal measurement from AGMA

Figure 5 Example of dresser geometry — another critical set of

Figure 11 Symmetric lead modification.

Figure 14 Example of profile inspection and evaluation.

Name _______________ Job Title _

Signature _______________ Date _