Gear Grinding: Software Update

JUN
GEAR 2017
GRINDING
• Latest Technology
• Twist Control Grinding
Software
Update
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 EMO in Hall 26!
www.star-su.com
contents
JUN
®
2017
22
features
technical
22 Gear Grinding Today
A look at some recent upgrades. 46 Ask The Expert
Ground and hobbed globoidal worm sets.
28 Wind Turbine Gearbox Reliability
Modeling, Instrumentation and Testing. 48 Twist Control Grinding
Process updates, i.e. — control of flank twist — for
hard-finishing gears.
30 Testing 1, 2, 3…
What’s New and Noteworthy in Software 54 Surface Structure Shift for Ground Bevel Gears
Applications in 2017? Influencing axis positions in each line of Axis Position
Table with small, pre-determined, or random amounts
34 Anatomy of a Rebuild
Nuttall Gear Taps Machine Tool Builders for 66 Designing Very Strong Gear Teeth Using High
Shop Floor Upgrades. Pressure Angles
Method of designing and specifying gear teeth with
much higher bending and surface contact strength
(reduced bending and surface contact stresses).
Vol. 34, 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 2017

[www.geartechnology.com]
Gear Shaping
Gear Hobbing
Vertical Grinding
Surface Grinding
Specialty Machines
New 10-4 Gear Shaper
The Fellows 10-4 gear shaper delivers the accuracy and speed required to shape gears and keyways
efficiently and accurately. The 10-4 is available with an electronic helical guide for the ultimate
flexiblility in gear shaping applications. With our 5th & 6th axis capability, stroke length and
position can be precisely controlled through the CNC. When coupled with our new HMI, the 10-4 is
an intuitive and versatile gear shaper for applications in automotive, aerospace, and job shops.
Learn more about the full line of New Fellows Gear Shapers
www.bourn-koch.com/fellows
www.bourn-koch.com
[email protected]
815-713-2367
Proudly designed, engineered, and built in America.
contents
® Vol. 34, No. 4
departments
06 GT Extras
Check us out — www.geartechnology.com — for
latest videos, blog postings, social media and
events.
09 Publisher’s Page
Get Smarter at Gear Expo.
10 Product News
Liebherr expands ChamferCut for new applications;
Sandvik Coromant new insert grade designed for
turning in unstable conditions
80 Industry News
AGMA elects James Bregi — president Doppler
Gear — new AGMA chairman of the board; Toyoda
Americas opens Great Lakes Technical Center;
Kapp Niles unveils new metrology division; Seco/
Warwick awarded production company of the year.
84 Calendar of Events
July 5–6: International VDI Congress-Drivetrain for
Vehicles, Bonn, Germany;
August 21–22: Design and Production Engineering
2017, Birmingham, U.K.;
September 6: AGMA 2017 Bevel Gear System
Design, San Diego, CA.
86 Advertiser Index
How to find every supplier in this issue.
87 Subscriptions
Sign up or renew your free subscription.
88 Addendum
Babbage’s Engines
JUN
GEAR 2017
GRINDING
• Latest Technology
• Twist Control Grinding
Software
Update
www.geartechnology.com THE JOURNAL OF GEAR MANUFACTURING

Cover photo curtesy of Liebherr

Liebherr Performance.
Gear hobbing machine LC 180 DC Gear hobbing machine LC 300 DC Chamfering machines LD 180 C and LD 300 C Chamfering in the work area
Simultaneous chamfering with ChamferCut –

The best and most economical solution
Established process in gear production
Very precise chamfer geometry
Premium chamfer quality and reproducibility
No bulging or material deformation
Standard tooth-root chamfering
Very long tool life
Lower tool costs compared to alternative processes
Liebherr Gear Technology, Inc.

1465 Woodland Drive
Saline, Michigan 48176-1259
Phone.: +1 734 429 72 25
E-mail: [email protected]
www.liebherr.com
GT extras
THE GEAR INDUSTRY’S INFORMATION SOURCE
www.geartechnology.com
RANDALL PUBLICATIONS LLC

1840 JARVIS AVENUE
ELK GROVE VILLAGE, IL 60007
(847) 437-6604
FAX: (847) 437-6618
EDITORIAL
Publisher & Editor-in-Chief
Michael Goldstein
[email protected]
Gleason Carbide Dry Hobbing: Associate Publisher & Managing Editor
The 100HiC features an integrated chamfering/deburring unit to eliminate burrs on tooth Randy Stott
flanks. The machine handles any geared profile which can be hobbed, up to a diameter of 100 [email protected]
mm (120 mm on request) and module 3 mm (optionally module 4 mm). Check out a video on Senior Editor
the process at www.geartechnology.com/videos/Gleason-Carbide-Dry-Hobbing/. Jack McGuinn
[email protected]
Senior Editor
KISSsoft Single Stage Gearbox Matthew Jaster
[email protected]
Modeling: Associate Editor
In this short tutorial, KISSsoft Alex Cannella
[email protected]
shows how quickly a user can
Editorial Consultant
define a gearbox using KISSsys Paul R. Goldstein
software. Learn more about the Technical Editors
software at www.geartechnol- William (Bill) Bradley, Robert Errichello,
Octave Labath, P.E., John Lange, Joseph
ogy.com/videos/KISSsoft-2017- Mihelick, Charles D. Schultz, P.E., Robert
Modeling-A-Single-Stage-Gearbox/. E. Smith, Mike Tennutti, Frank Uherek
DESIGN
Art Director
Event Spotlight: Gear Dynamics and Gear Noise Course David Ropinski
[email protected]
The purpose of this unique short course is to provide a better understand-
ADVERTISING
ing of the mechanisms of gear noise generation, methods by which gear Associate Publisher
noise is measured and predicted and techniques employed in gear noise & Advertising Sales Manager
Dave Friedman
and vibration reduction. Over the past 38 years more than 2,000 engi- [email protected]
neers and technicians from over 370 companies have attended the Gear Materials Coordinator
Noise Short Course. For more information, visit www.geartechnology.com/ Dorothy Fiandaca
news/7976/Gear_Dynamics_and_Gear_Noise_Course/. [email protected]
China Sales Agent
Eric Wu, Eastco Industry Co., Ltd.
Tel: (86)(21) 52305107
Fax: (86)(21) 52305106
Cell: (86) 13817160576
[email protected]
CIRCULATION
Stay Connected Circulation Manager
Carol Tratar
Join the Gear Technology [email protected]
Facebook group at
Circulation Coordinator
www.facebook.com/ Barbara Novak
groups/210890932629794/ [email protected]
Gear Talk:
Our resident blogger Chuck Schultz RANDALL STAFF
President
discusses a variety of gear manu- Follow us on Twitter Michael Goldstein
facturing topics including new tech- twitter.com/#!/Gear_Technology Accounting
Luann Harrold
nologies and innovations, company
slogans, summer jobs and the impor- Connect with us on LinkedIn
tance of taking chances and risks in www.linkedin.com/groups/Gear-
Technology-Magazine-3893880
gear design and development. Read
these and other entries at:
Subscribe Online
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subscribe.htm

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[
HERA ]
Our Technologies, Your Tommorow
Close the
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Downtime is a black hole that impairs productivity, kills

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publisher's page
Get Smarter
at Gear Expo
As I sit here working on this editorial, it’s already Publisher & Editor-in-Chief
Michael Goldstein
late Spring. Most days have been under 60° here
in Chicago, and rain almost every day is the norm.
So, before we get distracted by warm breezes and summer We also hope that when you come to Gear Expo, you’ll visit
blooms, I want to talk about the Fall. us in our booth (#1022). Two years ago, we presented the
This is a Gear Expo year, and in October, the American Gear first ever live edition of our popular “Ask the Experts” col-
Manufacturers Association (AGMA) will put on its biennial umn. We had four sessions — Gear Grinding, Cutting Tools,
exhibition in Columbus, Ohio. You might think that October Gear Design and “Ask Anything,” — featuring experts such as
is still a long way off, but summer can be fleeting. All it takes is Dr. Hermann Stadtfeld of The Gleason Works, Dr. Hartmuth
getting busy with a project or a new business opportunity, and Mueller of Klingelnberg, Dr. Andreas Mehr of Liebherr, and Dr.
months can go by in the blink of an eye. So I want you to start Karsten Stahl, head of the FZG research group at the Technical
thinking now about Gear Expo and the many benefits you can University of Munich, as well as our own technical editors,
get by attending. Chuck Schultz and Octave Labath. All of these people made
As always, you can expect all of the suppliers to our industry themselves available to our live audience to address problems
to exhibit their latest technologies, including new machinery, and answer questions. It was such a resounding success, that
processes, tooling, workholding and more. Additionally—and we’re doing it again at the 2017 show. Although we’re still final-
perhaps more importantly—this is a unique opportunity for izing our lineup, you can anticipate a similar level of gear-relat-
you to meet and interact with a wide variety of people from ed technical knowledge and experience among our experts. So,
these exhibitors. These companies are not at Gear Expo just if you’re having a particular design, manufacturing or any other
to sell you something. They’re there to educate you as well. So type of problem relating to gears, this is a great opportunity to
you can expect to meet with not only salespeople, but also the learn more.
dedicated gear industry professionals who are involved with As if that’s not enough, there’s even more to learn off the
engineering, maintenance and installation of the latest technol- show floor. Leading up to and overlapping the first day of
ogy, along with the key corporate leaders who provide valuable Gear Expo, AGMA will be running its Fall Technical Meeting
insight into our industry. (October 22–24), which is a yearly offering of the latest tech-
So don’t just go to the show thinking about the new machines nical articles, papers and presentations. This year’s batch of
you might like to purchase. Instead, go there thinking that this sessions includes a great mix of cutting-edge technical discus-
is the best and most efficient opportunity you’re likely to have sions and basics, so it’s a great learning opportunity for both the
to tap into the greatest wealth of gear manufacturing knowledge experienced gear engineer and the newbie.
on the planet. These people work with companies like yours all For more information about the show, including all the edu-
over the world. They know things about how your peers and cational opportunities available there, visit www.gearexpo.com.
competitors operate. They’ve probably already helped solve Register to come to the show. Make plans to stay as long as you’re
problems for others that you’ve only just recently become aware able. I’m confident you’ll be rewarded by what you find there.
of. Going to Gear Expo isn’t just a shopping trip. It’s a learning
expedition.
And it’s also an important opportunity for those of you who
don’t make gears, but buy them. It’s an often overlooked part of
the show, but one that’s gaining in importance. More than 50
gear and gearbox manufacturers are slated to exhibit this year,
including manufacturers of cut metal, powder metal and plas-
tic gears, as well as manufacturers of custom gearboxes for a
wide range of applications and industries. According to AGMA
President Matt Croson, Gear Expo will continue its evolu-
tion from a gear manufacturing show into a more complete
mechanical power transmission show. So, if you design, buy or
use gears or gear drives, I think you’ll find just as much at Gear
Expo as your gear manufacturing counterparts.
June 2017 | GEAR TECHNOLOGY 9

product news
Liebherr
EXPANDS CHAMFERCUT FOR
NEW APPLICATIONS
Liebherr has optimized its gear hobbing
machine portfolio for the ChamferCut
process and now offers enhanced tech-
nologies with increased cost-efficiency.
Additional machining is now no longer
required following chamfering in the
Liebherr ChamferCut unit. As a result,
chamfering can be performed more pre-
cisely, reliably and economically than
with competing processes, such as press
deburring. ChamferCut is a precise, reliable and
cost-effective process from Liebherr.
The ChamferCut process enables a
complete and even chamfer right down
to the tooth root. There is no need for
a second cut, which is often required chamfering include fast retooling and grated automation solution enables hob-
during the deformation-based deburr- simple adaptation in the case of varying bing and simultaneous chamfering of
ing process for the removal of build-up flank modifications, in addition to user- workpieces with a maximum diameter of
material. As the exact chamfer shape friendly software. Simple adjustments or 180 mm and a module of 3.5 mm.
is generated, there is no effect on the corrections are also possible via the CNC
material structure, unlike with deforma- axes. In general, dry and wet machining Gear hobbing machine LC 300 DC
tion-based processes. An optimal start- is possible with the optimized machines. With the LC 300 DC gear hobbing
ing point is created for downstream hard The machine tools are flexibly automat- machine workpieces with a maximum
gear finishing, through grinding or honed via a plastic chain conveyor or a pal- diameter of 300 mm can be produced
ing. The quality of the chamfer offers not letizing cell. The automatic loading is very economically, with a high gear cut-
only very precise chamfer geometry, but affected by the flexible ringloader printing quality and precise chamfer quality.
also high chamfer quality and reproduc- ciple. Alternatively, the loading can also Workpieces up to module 6.5 mm can be
ibility. The tool costs are also lowered, be done using a robot or gantry. The fol- hobbed and simultaneously chamfered.
which in turn leads to a low amortiza- lowing machine types are equipped with
tion period of the machine. the integrated ChamferCut unit: Chamfering machines LD 180 C and
LD 300 C
User-friendly control system with Gear hobbing machine LC 180 DC The LD 180 C and LD 300 C are com-
flexible automation capacity The established LC 180 DC with inte- pact stand-alone machines whose main
In contrast to press deburring, the grated ChamferCut unit is a very com- task is the chamfering of gears. They can
advantages for the customer during pact gear hobbing machine. This inte- be integrated easily, quickly and cost-
effectively into all existing production/
The Liebherr LC 300 DC gear hobbing machine with integrated manufacturing lines.
ChamferCut unit for chamfering parallel to machining.
Chamfering in the work area

The classic ChamferCut process with the
chamfer cutters on the hob arbor can be
retrofitted on all existing Liebherr gear
hobbing machines with Siemens 840 D
control and higher.
For more information:
Liebherr Gear Technology, Inc.
Phone: (734) 429-7225
www.liebherr.com

THE KLINGELNBERG P-MACHINE
High-precision measurement even on the shop floor –
with Klingelnberg Ambience Neutral Technology
UPCOMING TRADE FAIRS:

SUBJECT TO CHANGES
EMO 2017
September 18 – 23
Hanover, Germany
Measuring directly on the shop floor saves time and money.

Temperature-neutral machine technology
Klingelnberg precision measuring centers with Ambience Neutral based on physical and numerical methods
Technology feature an unbeatable and robust design for use on
the shop floor.
Robust machine design:
Klingelnberg Ambience Neutral Technology – long-established resistant to dust, dirt and humidity
proven technology for high-precision measurement.
Want to measure on the shop floor? Already have a Klingelnberg? Optional insulation against
Contact us at “[email protected]” vibration transmitted through the floor
or visit us at www.klingelnberg.com/en/news/product-highlights
BEVEL GEAR TECHNOLOGY MEASURING TECHNOLOGY CYLINDRICAL GEAR TECHNOLOGY DRIVE TECHNOLOGY
product news
Heller Machine Tools

HF SERIES DESIGNED FOR COMPLEX PRISMATIC PARTS
Heller Machine Tools introduces its HF
series 5-axis horizontal machining cen-
ters to North America for machining
complex prismatic parts from lighter,
smaller workpieces to heavier workpiec-
es up to 800 kg table load. In the series of
two machines, the fifth axis is provided
by the workpiece on a swiveling trun-
nion with rotary table or a pallet chang-
er for higher volume production. Users Random Bin Picking
can specify from a range of four spindle
packages based on the material. Spindle
speeds up to 18,000 rpm and torque up
to 354 Nm are available.
Automation
According to Heller, the main tar-
get groups of the HF series are the gen- It’s the ultimate
eral machine industry and automotive The basis for production efficiency.
industrial challenge.
suppliers. The two new machine mod-
els are Heller’s entry into a popular size Made
grated into a rotary in
tableGermany.
See the
on a trun-
solution at Liebherr,
Fastems or Schuler.
range for these industries. The HF 5500 nion, the HF machines are designed IMTS Booth
ContraryN-6930.
to conventional 5-axis
offers a work area of 900 × 950 × 900mm for 5-sided machining
Pallet Handling andandsimultane-
Storage-System machining PHScenters,
– Heller’s concept is
ous 5-axisThe With image recognition software,
(X/Y/Z), and the smaller HF 3500 has flexible automation for machining centers
machining. The HF machines not only based on single-part clamping
a work envelope of 710/750/710mm may alternatively be equipped with a a
Machining fixtured parts in a single setup?
�
robot,but and a
provides sophisticated
the possibility of multiple
(X/Y/Z). Batches and volumes vary?
lift-and-rotate
�
pallet changer for handling
series strategy,
clamping or the the Liebherr
clamping of very large
Need flexibility to mix parts or introduce new parts?
solution picks up parts from cases using
�
With three linear axes in X, Y and Z 5-sided production. Standardized

Need an automation
� solution forpallet
a variety components
of machine tools of (transmission
different
make, new or used?
and two rotary axes in A and B inte- automation solutions may be supplied by a‘window-type’
container, fixtures).
and then
Our PHS can improve your machine accurately positions them
utilization and enable lights-out operation onto fixtures, production
Complete flexibility in hardware and software
lines, or assembly lines.
�
Three platforms, payloads 500 - 6500 kg

�
� Front access for manual operation
� Retrofit? No problem! The potential for
7th WZL
productivity and efficiency
improvements is huge.
Gear Conference
hosted by Liebherr Gear Technology
July 18 and 19, 2017
at the Sheraton Ann Arbor
WZL presentations from its research portfolio will include:

Gear design • Manufacturing and testing • Plus presentations from Liebherr
Liebherr Automation Systems Co.

1465 Woodland Drive
Cost: $260 per attendee. Saline, Michigan Liebherr Automation Systems Co.
48176-1259
1465 Woodland Drive
Saline, Michigan 48176-1259
To register, email [email protected]
Phone.: +1 734 429 7225
Phone.: +1 734 429 7225
www.liebherr.com
The Group
www.liebherr.com [www.geartechnology.com]
One machine, two “pick-up” work spindles.
Reduce your set-up time with the KX100 DYNAMIC.
The KAPP machine concept reduces the auxiliary process times.
Small footprint even with complete coolant filtration system

Latest Kapp grinding technology with options for:
- automatic arbor changing - multi-rib dresser
- on-board inspection - bias targeting and more
Electrical cabinet permanently attached shortens installation time
Pick up spindle loads and unloads part directly from pallet or two position nests
Want more information? -Give us a call!
KAPP Technologies
2870 Wilderness Place Boulder, CO 80301
kapp-niles.com [email protected] (303) 447-1130 precision for motion.
product news
The NC toolchanger is equipped with two NC axes for short idle

times and consistent operation. The chain-type tool magazines capaci-
ties are: HSK63: 54, 80 and 160 or HSK100: 50, 100 and150.
As standard, Heller offers the SC63 SpeedCutting unit (18,000 rpm,
100 Nm) equipped with an HSK-A 63 spindle taper. Optionally avail-
able is the PC63 PowerCutting unit (12,000 rpm, 201 Nm), also
equipped with an HSK-A 63 spindle taper, as well as the SC100
SpeedCutting unit (12,000 rpm, 201 Nm) and the PC100 PowerCutting
unit (10,000 rpm, 354 Nm), both equipped with an HSK-A 100 spin-
dle taper. The HF machines provide a rugged 8000 (HF3500) and
10,000 Nm (HF5500) of feed force for handling even the most difficult
materials without interruption or strain.
SPIRAL BEVEL GEAR CUTTING MACHINE Recently, Heller demonstrated the

capabilities of the HF series. Using a
HIGH PRECISION, GOOD RELIABILITY, GREAT VALUE 100 mm diameter face-milling cutter, a
chip removal rate of 470 cm3/min was
achieved, machining 1.2312 steel with
a feed of ap 3.5 mm and an engagement
width of ae 75 mm. An optional Speed
Package enables acceleration of up to
10m/s2 and rapid speeds of up to 90m/
min to be achieved on the HF series.
This provides a reduction in chip-to-
chip times of approximately 10 percent.
HF series machines are equipped with
a Siemens control and a double pivot-
ing main operator panel with a 24-inch
touchscreen as well as a newly devel-
oped Heller user interface for maximum
ease of operation.
CNC Spiral Bevel Gear Cutting Machine
Heller Machine Tools
Siemens 840D Controller, utilizing five (5) synchronized axes Phone: (248) 288-5000
LUREN designed easy to use, Microsoft Windows© based software www.heller.biz
Precision cutting to 100 mm O.D., with maximum Module of M3
Cup type milling cutter with HSK tool holder & 4,000 RPM Spindle
Easy adjustment of contact pattern by point, click & drag
Also Available：LUREN’S LVG-100 Spiral Bevel Gear Grinding Machine
Our Gear Cutting Tools Hobs Shaper Cutters Master Gears

For over 20 years of manufacturing, Luren
has been offering a wide variety of custom
and standard gear cutting tools using the
highest quality materials and accuracy to
ensure your longest possible tool life.
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 : [email protected] Email : [email protected]
Website : www.luren.com.tw Website : lurenusa.com

Sandvik Coromant
NEW INSERT GRADE DESIGNED FOR TURNING IN
UNSTABLE CONDITIONS
Cutting tool and tooling system specialist Sandvik Coromant has introduced its
GC4335 insert grade for the turning of steels where unstable conditions or vibra-
tion issues prevail. GC4335 is designed to bring about secure and predictable
machining as well as shorter cycle times and better machine utilization through
reduced stoppages and longer insert life. Customers will benefit from an improved
process with less risk of insert breakage as well as reduced cost per component
and faster return on investment.
GC4335, which features Inveio coating technology for maximum thermal
protection, offers greater steel turning
endurance through improved edge-line
security in comparison with the previ-
ous generation grade, along with greater
resistance to flank wear, plastic deforma-
tion and crater wear.
“The new GC4335 is particularly suited
for uneven forged surfaces, the turning of
which can lead to frequent insert changes
due to fatigue and failure,” explains Bimal
Mazumdar, product manager - turning.
“Slowing down an operation to replace
a broken insert means less production.
When production is slower, fewer parts get
completed per cycle, and that affects over-
all profitability.”
The introduction of GC4335 will ben-
efit general engineering shops, as well as
automotive OEMs and tier suppliers and
subcontractors in the oil and gas sec-
tor. Typical components include tubes,
valves, crankshafts, differential housings,
flanges and rings to list a few.
Underlying reasons behind the per- Mark Vincent
formance of GC4335 include a new sub- Schafer A-Team member
strate that is well balanced between reli-
able toughness and resistance to plastic
deformation. In addition, a new alumina
coating delivers efficient heat transfer
from the cutting zone to act as a heat
Engineering manager and
barrier, and the columnar MT-TiCN
inner coating offers improved resistance
world-class gearhead
against abrasive wear. A yellow TiN coat-
ing on the insert flank allows for easy Mesh. According to Mark, that’s what Schafer Industries’
wear detection. engineers excel at doing. We understand the basic geometry
For more information: of most gear tooth forms is the involute curve. It defines the
Sandvik Coromant shape of the tooth flanks and how well a gear meshes. By
Phone: (800) 726-3845
www.sandvik.coromant.com knowing how to make even the slightest modifications to
this curve we can add life to your gears and minimize your
gear set noise. Let’s talk.
INDUSTRIES
schafergearheads.com

product news
Mahr Federal
OFFERS LATEST VERSION OF MARCOM
METROLOGY SOFTWARE
Mahr Federal is now offering its MarCom metrology software ver-
sion 5.2 as a free download from Mahr’s website. MarCom 5.2 is a
full-featured metrology software interface for connecting measur-
ing instruments by cable or wireless. It enables direct transfer of
measured values into MS Excel, SPC software, or text file, and can
manage signals from up to 32 measuring instruments connected
by wireless and 128 connected via cables using USB.
“Taking measurements on the shop floor and transmitting
them wirelessly speeds up the quality assurance process,” said
George Schuetz, Mahr Federal director, precision gages. “When
measuring on the machine or on larger workpieces, for exam- MarCom 5.2 software enables fast and easy setup of measur-
ple, there is no need to run troublesome cables. This speeds ing stations with wireless data transfer to the PC. The MarCom
setup and provides more efficient data processing, especially for cell control is highly flexible. Measured values from connected
quality control in production or incoming goods.” devices can be automatically transferred into separate Excel col-
Wireless data transmission also simplifies the recording and umns, tables, or files ensuring the reliability of measurement
documenting process, especially in the networked factory of data documentation. At the same time, the MarCom software
Industry 4.0. By pressing a button on the instrument or using ensures that readings can be passed on through an integrated
a keyboard command, timer, remote control or foot switch, virtual interface box to an SPC/CAQ software such as Q-DAS
acquired data is sent from the gage to an i-stick radio receiver or Babtec.
plugged into the USB port of a computer. Each i-stick can receive For more information:
data from up to 8 gages using “Integrated Wireless.” For those Mahr Federal Inc.
measuring instruments that do not have an “Integrated Wireless” Phone: (401) 784-3100
www.mahr.com
interface, Mahr can add an external transmission module.
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 [email protected] for a quotation.
DTR has sales territories available. Call for more information.

U.S. Office Location (Chicago) Email Headquarters
inquiries to: [email protected]. 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

Walter
MILLING CUTTERS PROVIDE
VERSATILITY FOR WIDE RANGE OF
APPLICATIONS
Walter has added to its range of solid carbide
milling cutters with the introduction of
its MC232 Perform product line.
These three versatile, cost effec-
tive new cutter types are avail-
able with two, three or four
teeth, in a diameter range of 0.08
in. to 0.79 in. (2 to 20 mm) from a
0.24 in. (6 mm) shank diameter with
a Weldon shank.
This marks the first time that solid
carbide milling cutters have been includ-
ed in the Perform line from Walter,
which is designed to be highly economi-
cal and suitable for use in a wide range
of applications, key advantages for shops
that frequently machine smaller quanti-
ties. The properties of the new MC232
Perform milling cutters are particularly
beneficial for users whose top priority is
the universal applicability of their tools,
rather than simply tool life.
Universal applicability is also mir-
rored in the technical features of the
MC232 Perform milling cutters. Thanks
to their geometry with center cutting
edge and 35 degrees spiral, as well as
their WJ30ED grade, these new corner/
slot milling cutters are suitable for all
common milling operations such as lat-
eral milling, full slotting, pocket mill- Tricia Robertson
ing, ramping and helical plunging. They Schafer A-Team member
can be used in industries ranging from
mechanical engineering, mold and die,
to the automotive and energy industries.
Walter USA, LLC
Customer relations specialist
Phone: (800) 945-5554
www.walter-tools.com/us and world-class gearhead
Pro-active. That’s Tricia’s stance on customer service.
She knows to keep your lines running Schafer Industries
must head off gear problems or nip them in the bud fast.
As our voice on the frontline, she works closely with our
engineering, production, quality and shipping teams to get
you solutions. There’s no reason for you to be frustrated.
Let us prove it.
INDUSTRIES

product news
BVL Oberflachentechnik
OFFERS CLEANING SYSTEMS FOR AUTOMOTIVE
INDUSTRY
The absolute necessity for clean com- While the component is deburred, the
ponents in the automotive indus- empty workpiece holders in this special
try requires reliable cleaning technol- application move through a washing unit
ogies. With longstanding experience integrated into the high pressure system.
in this field, the manufacturer BvL This positions the deburred component
Oberflächentechnik produces suitable on the cleaned workpiece holder, pre-
cleaning systems which are always tai- venting renewed soiling through residue.
lored to special customer requirements. Because of its compact design in con-
The NiagaraDFS basket washing sys- tainer form, the high pressure deburr-
tem is BvL’s answer to especially high ing system can be ideally integrated into
cleanliness requirements. The flood/ the production process. BvL offers all
spray system with revolving wheel tech- required systems from a single source:
nology ensures thorough all-round from pre-cleaning, deburring and fine
cleaning through rotation of the parts cleaning to drying and cooling. The
baskets or parts carriers around the hori- machines and components made of
zontal axis. The inline material flow con- high quality stainless steel are perfectly
cept shortens ancillary times to a mini- matched and can be individually adapt-
mum, significantly reducing cycle times ed: the high pressure deburring system
and increasing capacity. from LTH Castings was also combined
BvL also offers expertise in the field with a pre-cleaning unit and a final fine
of deburring. For the cleaning of gear- cleaning stage.
box parts for a large German automotive For more information:
manufacturer, the Slovenian company Bernard Van Lengerich Gruppe
LTH Castings invested in the Geyser Phone: +49 (0) 5903 951-0
www.bvl-group.de
high pressure deburring system with an
integrated industrial
robot. The Geyser reli-
ably removes swarf and
burrs with a high pres-
sure water jet through
multiple rotating noz-
zles or single lances
which are directed spe-
cifically at the critical
areas of the component.
Short cycle times make
the system particularly
efficient and suitable for
series production.

Seco/Warwick
DELIVERS VACUUM HEAT TREATMENT SYSTEM
TO GALVAMET
Seco/Warwick is developing a vacuum heat treatment system equipped
with a 10 bar abs. gas quenching system, the sixth in a series of systems
designed by the company that power the Galvamet industrial park. The
new system will increase their production capacity for the heat treatment
of components for the aviation sector.
The Seco/Warwick system to be delivered to Galvamet is designed for
a wide range of industrial heat treatment applications including quench
hardening and tempering, degassing, annealing, solution heat treatment,
brazing and others.
“Galvamet has been cooperating with Seco/Warwick for a few years
now. Seco/Warwick has been the part-
ner that fully understands our busi-
ness needs and delivers innovative and
state-of-the-art technologies, increasing
our production capacity and improving
the finished quality of our heat-treated
products. With the addition of the Seco/
Warwick high vacuum furnace, we aim
to deliver excellent and durable parts to
our demanding customers in the most
cost-effective way,” said Ales Slechta,
executive manager of Galvamet.
“Seco/Warwick’s long term cooper-
ation with the leading manufacturers
of components used for production of
airplanes, automobile, tools and others,
along with the extensive industry knowl-
edge and access to the latest technolo-
gies, has made our solutions the solu-
tions of choice. The system which is
going to be installed at the Galvamet
facility guarantees that our customer will
produce the best quality products and Cory Garman
meet the requirements of AMS2750E,” Schafer A-Team member
said Maciej Korecki, vice president, busi-
ness segment vacuum at Seco/Warwick.
Precision is critical as any deforma-
tion in a metal case structural properties
can cause tragic aircraft accidents. Seco/
Gear grind lead
Warwick solutions not only enhance the
physical properties of the metal, but are
and world-class gearhead
also energy efficient and environmen-
tally friendly. Challenges. That’s what Cory thrives on when he’s precision
For more information: grinding heat-treated gears. He, and our teams at Schafer
Seco/Warwick Corporation Industries, are constantly asked to meet custom-engineered
Phone: (814) 332-8400
www.secowarwick.com specifications for gears and drivelines. They respond to every
opportunity with decades of honed skills and collective
can-do attitudes. Re-dos are very rare and that certainly
reduces your challenges. Let’s meet.
INDUSTRIES

product news
LMT Tools
OFFERS PRECISION TOOLS FOR MEDICAL
INDUSTRY
The human body is a miracle of
nature. In various areas, modern med-
icine is able to imitate this mira-
cle: Prosthetics, for example,
take over important func-
tions. They form human Tools, quick
body parts and limbs in response times and
precise detail and make fast request processing are
Quality Solutions Since 1960 natural movement pat- taken for granted. This way, cus-
terns possible. For the tomers benefit from the experience
complex processing of pros- of the LMT Tools experts in every step
thetics — such as artificial knee in the production process.
joints — LMT Tools offers precise cus- Sophisticated materials such as tita-
tomized tools. nium or CoCrMo are used to produce
In the field of medicine, authoriza- artificial joints. LMT Tool’s customized
tions are required for certain machin- tool solutions and portfolio of standard
ing methods. For the experts at LMT precision tools for medical technolo-
Trico Corporation
LAUNCHES SENSEI LUBRICATION SYSTEM
Trico Corporation, a provider of lubri- the Internet of Things era.”
cation management solutions, recently The first wireless sensors available as
introduced Sensei, a real-time lubrica- part of the Sensei system are oil level
tion intelligence system. Sensei wire- sensors designed to accompany Trico’s
lessly transmits oil level and ambient line of 8-oz. Opto-Matic vented and
air temperature to a customizable, web- closed constant level oilers. Pumps,
based dashboard. As a result, users gain motors, gearboxes, fans, blowers and
real-time input on machine status and other equipment use constant level oilers
maintenance requirements. to maintain a consistent fluid level.
Sensei can: Industrial and manufacturing applica-
• Reduce inspection time from hours to tions include those in machining, pet-
minutes per week. rochemical, chemical processing, pri-
• Standard Components • Reduce requirements for personnel to mary metals, pulp and paper and more.
visit difficult- or dangerous-to-access “Sensei has helped us rule out and iden-
• Made to Print Parts & areas. tify problems,” says Mike Walton, ICML,
• Help avoid downtime by providing
Assemblies alerts and warnings. MLT-II, Mechanical
• Enable organizations to operate more Technician at Irving
efficiently by performing proactive, Tissu e, St . John ,
• Design & Engineering Ne w Br unswick.
data-driven maintenance.
Irving Tissue tested
“The launch of Sensei represents a Sensei on the Yankee
new ability to generate meaningful data Exhaust Fans that
faster and more efficiently than ever assist in the dr y-
Nordex.com before. As a result, we are uniquely posi-
tioned to help customers develop cost-
ing process. Walton
notes that the reli-
[email protected] saving strategies and reduce the massive ability team at first
[email protected] pressures of reliability,” says Jim Jung, thought one fan had
Phone: (800) 243-0986 president, Trico. “In combination with an oil leak because it
the services from the Trico Analysis lost so much oil in a
or Call: (203) 775-4877 Center, Sensei enables us to redefine short period, but his-
lubrication management strategies for torical data provided

gy have special geometries and
coatings. They make precise cut-
ting and processing within narrow
tolerances possible. tomorrow’s
machines
L M T ’s DHC Hard l i ne s e r i e s
tools facilitate trochoidal milling.
Machining using circular feed motion
today
significantly shortens processing
time — while maintaining high qual-
ity and excellent process reliability.
This means that even the standard
tools by LMT Tools provide innova-
tive solutions for sophisticated forming
and complex components which are
required in the field of medical tech-
nology. let us help you find the
LMT USA Inc.
Phone: (847) 693-3270
right grinding solution
www.lmt-tools.com
800-843-8801
The USACH 100-T4 CNC ID/OD This machine offers a variety of features
precision grinding machine is ideally and options like:
by Sensei showed that there were peri- suited for a variety of different • four motorized grinding spindles
ods as long as four to five months where industries. Combining ID, OD, face, • high precision measuring probe
oil level stayed constant. taper, radii and contour grinding in • latest torque motor based
“On fan 200-190-21, Sensei enabled one chucking. Thanks to the generous B-Axis design
us to rule out a leak and look for other cross axis travel of 500 mm/19.68” • automation
causes,” says Walton. “Conversely, fan (X-Axis), the machine processes parts • high precision hydrostatic work
100-190-53 leaked constantly. On closer up to 450 mm/17.7” in diameter at head swivel B1-Axis
examination, we found it had a leak- a weight capacity up to 272 kg/500 lbs. • Siemens or Fanuc control
ing fitting going to the bearing housing,
as well as a bad seal. Work orders were
entered to correct those problems.” www.HardingeGrindingGroup.com
Trico Corporation
Phone: (800) 558-7008
www.tricorp.com
COME SEE THIS

MACHINE AT
FOR MORE INFORMATION VISIT

WWW.HARDINGE.COM/HMTS2017

feature
Gear Grinding Today

New divisions, open houses and the continued rise of the In-
dustrial Internet of Things — there’s been a lot going on in gear
grinding the past year. Here are a few highlights of what peo-
ple are doing in industry today.
Alex Cannella, Associate Editor
Gear grinding is growing at a second pass, a grinding wheel removes Company Spotlight: Kapp Niles
steady pace. It continues to be an the remaining stock without causing Metrology (KNM)
essential part of the gear manufacturing problems of overheating the workpiece, There’s a new Kapp Niles in town named
process, business is on the up and indi- which results in a fully dry process. The Kapp Niles Metrology GmbH (KNM).
vidual markets such as aerospace and structure with two spindles actuated by According to Bill Miller, VP — sales and
automotive are holding strong. While the linear motors and the use of more service for Kapp Technologies (KTLP),
there’s no imminent overhaul of the channels simultaneously ensures a chip- after KTLP acquired controlling inter-
industry or sudden shift in economic to-chip time of less than two seconds. est in U.S.-based Penta Gear Metrology
fortunes that gear grinders need to brace The SG 160 splits the X-axis into two in 2015, it was evident by customer
for, the industry is still moving forward, liner slides, each of which carries tool response that a full metrology product
and different machine manufacturers spindles. Both work spindles are in full line should be offered globally. KTLP
have come up with a few new ways to position control at any time. already distributed the larger metrology
compete for your dollar and provide The SG 160 Skygrind ensures cycle systems (R&P) built in Aschaffenburg,
added services for your gear grinding times at a low comparative cost to tra- Germany, and extending operations
needs. Here are a few of the latest oppor- ditional manufacturing solutions in the globally was an attractive prospect.
tunities and new technologies you might automotive industry. Further study indicated that with addi-
want to take advantage of. According to the manufacturer, the tional resources and technology from
SG 160 Skygrind is even faster than tra- Kapp, founding a new company would
Product Spotlight: Samputensili’s ditional dual table grinding machines, yield significant synergies. Hans Rauth
SG 160 Skygrind featuring a small footprint and lower and Chris Pumm agreed and become
The SG 160 Skygrind from Samputensili cost for auxiliary equipment. The most founding partners in the formation of
is the world’s first gear dry grinding important piece however is the elimi- KNM and bring familiar engineering
machine. This process removes the need nated need for cutting tools, creating an and technical staff with them.
for cooling oils during the hard finish extremely green machine. The new division launched on April 1,
grinding of the gear after heat treatment. To see the SG 160 in action, you can 2017 and Miller elaborated that demand
Roughly 90 percent of the stock allow- watch the video at www.geartechnology. from the company’s established custom-
ance is removed in the first pass using com/videos. er base is a primary focus of the new
a hobbing tool, and subsequently in the division, but growing demands in the
market as a whole for innovative metrol-
ogy solutions present exciting oppor-
tunities especially as part of Kapp’s
Industry 4.0 initiatives.
“Often we’re asked by customers: ‘who
do you recommend for measuring?’
They want to know what we use and
how we measure,” Miller said. “A couple
of times I’d ask if they wanted us to get in
this business. And they said: ‘would you,
please?’”
Kapp Niles has had their own metrol-
ogy technology built directly into their
grinding machines for over two decades
so it is a logical step. But while a built-
in measuring system offers closed loop
corrections for setup time savings for a
grinding machine, it isn’t certified to use
as the final measurement.

“It’s been a long time coming in that made in these high-end machines, so automatic pallet changer. The machine
we’ve heard this for decades,” Miller said. they are looking basically to adapt cer- also features a dual-frame design in
“The customers’ message is clear: why tain features to universal grinders so which the machining head is positioned
don’t you build a measuring machine so it gets them by, so to speak...These are in the middle of the machining area. The
that we can buy the system from you. kind of two contradictory trends, if you design is meant to improve the grind-
And so finally, we had the opportuni- will.” er’s rigidity, and thus accuracy, as well
ty and the time was right, and so we Meeting the demands of one of these as improve control of machining and
stepped into with the new entity: Kapp trends is the Hauser H40-400, a uni- transverse forces and reduce effects from
Niles Metrology.” versal jig grinder now being sold by the thermal expansion.
KNM is not meant to replace Penta Hardinge Grinding Group. The H40 Also in an effort to improve work-
Gear, and Miller emphasizes that the two comes with numerous base features, speed, the Hardinge Grinding Group
companies are highly complementary. including automatic taper grinding, an has incorporated internet connectivity
KNM will give Penta Gear’s products automatic grinding tool changer and an and other technologies that fall under
worldwide reach.
That said, there are more differences
between the two companies than just
the markets they’ll be selling to. They
will continue to release metrology solu-
tions that will cover different manufac-
turing needs and work with different
sized workpieces. Penta Gear’s products
primarily consist of analytical machines
capable of measuring workpieces up to
400 mm in diameter, recontrolled used
machines up to 650 mm, and gear size
(DOB) and double flank function-
al gages. KNM constructs custom gear
analytical machines with up to 5.5 m of
capacity, portable checkers, and integrat-
ed inspection systems.
“The existing products and unique
strengths of these companies together
provide a full range of products and ser-
vices to the market,” Miller said.
Hot Topic: Improving Workspeed

and Productivity
Hardinge Grinding Group’s General
Manager — Director of Sales, Daniel Rey,
has noted a number of trends amongst
the company’s customers. Most of them
surround a familiar desire: to reduce
setup time, and thus put out more prod-
uct faster. A common method that Rey’s
noticed is becoming more prevalent is to
grind multiple distinct features simul-
taneously, but notes that the manner in
which manufacturers are pursuing that
goal can vary depending on how deep
their pockets are.
“So we kind of see two trends,” Rey
said. “One area is for the high-end
machines, where cycle time is impor-
tant, where automation is important,
where grinding features simultaneously
is of importance. There is another trend
with sub-suppliers. They don’t have the
amount of investments available to be

feature GEAR GRINDING TODAY
the Industrial Internet of Things’ (IIoT) seeing wide adoption is in the field of and become standard tools a gear man-
umbrella. IIoT technology has become connectivity. Alongside numerous other ufacturer can expect to use to improve
increasingly relevant in every industry, machine manufacturers, the Hardinge productivity.
and gear grinding is no different. What Grinding Group has opted to design all “Some people that are well-read, they
is different is that now we’re reaching the their machines to leave the factory floor expect things to be available today,” Rey
tipping point where we see IIoT services capable of connecting to the internet. It’s said. “They don’t want to wait until the
become more widely adopted and, with a seemingly simple, almost innocuous future is here, so to speak.”
an increasing number of customers, even upgrade, but it’s also one that wouldn’t One of the primary benefits of inter-
expected. have been widely considered five years net connectivity is that it allows the
“Some of that we clearly see filtering ago. Now it’s a standard feature. And Grinding Group to connect to a machine
through now and becoming more and one can expect that other, more complex anywhere, even remote regions where
more of a requirement for customers in concepts related to IIoT — preventative they may not necessarily have an engi-
their buying decision,” Rey said. maintenance through self-monitoring neer on hand. When there’s a malfunc-
One area of IIoT technology that is products, for example — will follow suit tion or error, Hardinge’s team can trou-
bleshoot the machine online instead of
forcing the customer to wait an extra day
for an expert to arrive on-site, potential-
ExcE l - l E n c E aT wo rk ly reducing downtime.
“We try to basically become more
responsive and faster in our responses...”
Rey said. “If a customer calls, whoever
LARGE GEAR
is on the other line will tell you a cer-
tain set of information, which then the
GRINDING?
best way for us to verify would be to be
in front of the machine. And short of
being in front of the machine due to not
WE’RE FASTER!
having a local service engineer available
would be to access the machine online.”
Rey stressed that the technology is not
meant to replace Hardinge’s force of ser-
vice engineers. Instead, it’s designed to
provide customers more options to get
back on their feet as quickly as possible
Time is money. With our if something goes wrong with a machine.
new high speed, high accuracy Both avenues will still be available for the
continuous generating grinding customer to utilize at their discretion.
capability using multi-thread
wheels, we’re grinding gears as Product Spotlight: Klingelnberg’s
large as 1200 mm in diameter Cylindrical Gear Machines
and module 12 much faster During a two-day in-house show on
and more efficiently than form November 9 and 10 at the Ettlingen
grinding. Ober weier (Germany) works,
Klingelnberg presented its wide range of
We’re more flexible too, with Höfler cylindrical gear machines. A total
the same new platform offering of 13 exhibition areas at the Ettlingen
rough and finish profile grinding works were dedicated to showcasing the
and on-board dressing and company’s innovative and versatile solu-
inspection. tions as well as the very latest technolog-
ical processes.
We also excel at grinding gears T h e l at e s t d e ve l opm e nt f rom
as small as 2.00" in diameter. Klingelnberg enables direct networking
of a closed loop cylindrical gear machine
with a measuring device. This technology
ready to Excel? was previously only possible with bevel
contact: gear machines. “By transferring the estab-
lished Klingelnberg closed loop concept
for cylindrical gears, we link the machin-
815.623.3414 / www.excelgear.com ing centers with the measuring machine

and are therefore driving digitization meter-high Höfler HF 6000 cylindri- spiral bevel gears up to AGMA class 14
of gear manufacturing firmly forward,” cal gear cutting machine at the plant accuracy. It features a cup type CBN
explains Dr. Christof Gorgels, head of the entrance. The Höfler HF 6000 cylindri- grinding wheel and an HSK tool hold-
Precision Measuring Center product line. cal gear cutting machine for workpieces er designed to maximize stability and
“The closed loop concept for cylindrical has a diameter of up to six meters. provide quick tool replacement. Other
gears is based on an open interface and physical features include a Siemens con-
automates machine correction.” Product Spotlight: Luren troller, separate cooling system for the
To demonstrate how the latest Precision’s LVG-100 spindle and direct drive motors and a
Industry 4.0 compliant development The LVG-100 is Luren’s latest and most rigid high-speed spindle. The LVG-100
can be used for practical production, advanced 6-axis CNC machine to date. also has an optional probe for automatic
a VIPER 500 cylindrical gear grind- Designed to grind spiral bevel gears tooth positioning.
ing machine was networked with the efficiently and with high precision, the One feature not limited to Luren’s
P 40 measuring machine at the works. LVG-100 grinding machine can produce LV-series machines, however, is the com-
“We have been waiting for this inter-
face!” Willi Humbel, chairman of the
board of directors of Humbel Zahnräder
AG, commented. “This development
We’ll Keep You

will help us tremendously to simplify
SAFE
production of our toothed gears and
improve the quality of our components
at the same time.”
Digitization in production was the
main topic at the two-day event. Höfler
cylindrical gear grinding machines are
not only designed to be reliable and
highly-developed hardware, but the com-
pany’s GearPro software also guarantees
convenient machining and ensures maxi- Forest City Gear’s exceptional reliability means
mum efficiency in daily use. you’ll sleep better at night. Safeguard your next gear
In addition, attendees were able to production project.
obtain information about the wide range
of services of the machine construction 815.623.2168
company. With the Höfler Service Gate www.forestcitygear.com
remote maintenance concept, a global
communication network will be estab- BOOTH #606 Excellence Without Exception
lished in the future from the Ettlingen
Oberweier site. At the beginning of the
technology show, visitors already mar-
veled at the sight of a customized eight-

feature GEAR GRINDING TODAY
pany’s software. Designed and created by making our grinding machines.” more relaxed, personal, and focused set-
Luren’s software department, it’s designed According to Ditzler, the LVG-100 has ting compared to the traditional trade
to provide a friendly user interface by received a warm reception in the two shows,” David Drechsler, business devel-
generating automatic CNC programs and years it’s been on the market. The grind- opment manager — Americas at Haas
providing versatility for all types of gear ing machine has become a regular part Multigrind, said. “We bring our pros-
designs, including an automatic path gen- of Luren’s booths at trade shows. Luren pects up to date on recent and planned
erating compensation feature. took the LVG-100 on the road to the last innovations at Haas and we have time to
“With our software, minimal CNC Taipei International Machine Tool Show get more detailed and interactive feed-
code knowledge is needed to run our (TIMTOS) and Japan International back from our customers.”
machines, the operator simply needs to Machine Tool Fair (JIMTOF), where it Amongst their usual established prod-
input the specifications right from the received positive attention, and if you ucts, Haas used GrindDate to intro-
gear drawing, and our software actu- want to get a good look at it yourself, duce their latest wheel loading station.
ally generates the whole CNC pro- the LVG-100 will be at Gear Expo in The station is designed to operate with
gram,” Darian Ditzler, north american October. their Multigrind CA and CB machines,
sales representative at Luren Precision, five-axis grinding centers that are built
said. “It will suggest a machining pro- Event Spotlight: GrindDate 2017 using Haas’ Multicube design. The load-
gram, generate a grinding path, allow Amongst the numerous massive trade ing station system allows users to load
for modification of tip, root, chamfer, shows that happen every year, Haas wheels and wheel sets for more part
and crowning. Our software is intui- Schleifmachinen (German parent com- numbers, reducing setup and change-
tive and conversational, making it the pany of Haas Multigrind) put on their over time, and is capable of storing up to
best feature of our machines. Designed own open house show, GrindDate. 70 wheel flanges and 20 coolant nozzles.
as a turnkey machine, we can put our The show was designed to give attend- Alongside the latest technology from
machine on your shop floor and within ees an opportunity to learn about the the company, 18 presentations were
two or three days you can be grinding company’s products and latest develop- given at the show. English and German
production parts.” ments in a calmer setting than the fran- presentations covered a full range of
The LV-series machines are part of tic hustle and bustle of mainstay trade grinding and related technologies,
Luren’s ongoing focus on building high shows. Haas organized the show at their including grinding wheels, grinding flu-
quality, advanced CNC machines. headquarters in Trossingen, a small ids, wheel dressing, coolant filtration
“To make a high-quality machine German town on the edge of the Black and software, and Haas even brought
requires attention to every detail to Forest, to set the backdrop for the show’s in speakers from outside companies,
meet Luren’s requirements for high relaxed tone. including Oelheld, Kaiser and Krebs &
precision grinding and solid long “GrindDate is intended to encour- Riedel.
term reliability,” Ditzler said. “That age two-way communication with our 2017 was the second ever installment of
has always been our focus on customers and prospects, in a much Haas’s show, and according to Drechsler,
GrindDate 2017 outstripped its predeces-
sor with double the attendance.
Haas Multigrind LLC
Phone: (574) 268-0053
www.haas-schleifmaschinen.de/en
Hardinge Inc.
Phone: (607) 734-2281
www.hardinge.com
Kapp Technologies
Phone: (303) 447 1130
www.kapp-usa.com
Klingelnberg America, Inc.
Phone: (734) 470-6278
www.klingelnberg.com
Luren Precision
www.lurenusa.com
Phone: (847) 882-1388
Star SU LLC
Phone: (847) 649-1450
www.star-su.com
For Related Articles Search
grinding
at www.geartechnology.com

Industry Spotlight: The Future of
Automotive
In automotive, as with many other industries,
gear grinding is an unquestioned cornerstone
of the gear production process, and according
to Walter Graf, Reishauer’s marketing man-
ager, it will only continue to grow in impor-
tance, particularly with the rise of electric
cars. Though electric cars won’t be complete-
ly taking over the market any time soon, they
are expected to grow in popularity, and when
they do, it will be important that gear manu-
facturers are ready to meet new demands. To read about Reishauer's latest gear grinding technology, see the
technical article, "Twist Control Grinding," on page 48.
According to Graf, a primary
concern for electric cars will be gear
noise. When the usual petrol-based
motor is cut from an electric car,
one of the loudest remaining nois-
es comes from the gears, and Graf
believes that reducing that noise will
not only become a matter of con-
cern for automotive manufacturers
in the future, but also that reiterat-
ing on current gear grinding tech-
niques can provide the solution to
that demand.
Just last month, we took an in-
depth look at the outlook for the
automotive industry. If you want to
learn more about upcoming trends
gear manufacturers working in the
automotive industry should be keep-
ing tabs on, check out “Transmission
Throwdown” in the May 2017 issue
of Gear Technology or online at
www.geartechnology.com.
Product Spotlight: Liebherr’s IG

Opal 4.0 Technology
Liebherr has reiterated on past
designs and come out with their next
generation of internal gear tooth pro-
file grinding technology. IG Opal
4.0 allows users to change over from
external to internal gear grinding in
under a half hour and is compatable
and Universal Gear Company
with grinding disks 100 or 125 milli-
meters in diameter. 1605 Industrial Drive
Interested in hearing more about Auburn, CA 95603
Liebherr’s new technology? You can Phone: (530) 885-1939
find more details in our product new Fax: (530) 885-8157
section online at www.geartechnology.
com or in the May 2017 issue of Gear Call 530-885-1939 or visit
Technology. www.broachmasters.com

feature
Wind Turbine Gearbox Reliability

Modeling, Instrumentation and Testing.
Travis Histed and Chad Glinsky, Romax Technology, Inc.
A high number of wind turbine gearboxes do not

meet their expected design life, despite meeting
the design criteria of current bearing, gear, and
wind turbine industry standards and certifica-
tions. This, in turn, increases the cost of energy generated by
wind turbines. To investigate the root causes of these reliability
issues, the U.S. Department of Energy and National Renewable
Energy Laboratory (NREL) established the Gearbox Reliability
Collaborative in 2007, now called the Drivetrain Reliability
Collaborative (DRC), of which Romax Technology is an active
partner. The collaborative is focused on improving reliability by
better understanding loads, improving design tools, and refin-
ing testing practices. Figure 2 NREL 2.5 MW test stand with GB3 in background, and NTL
hydraulic system in the foreground. The NTL system is used to
A series of gearbox designs have been tested on the NREL 2.5 impart non-torque loads into the hub flange of the test article,
MW dynamometer in Colorado as part of this effort, with each simulating wind turbine rotor hub loads.
iteration containing strategic design elements used to validate
certain assumptions. Romax Technology and Romax InSight design, automotive and off-highway vehicle drivetrain design.
have been involved in the modeling, analysis, design, and test- The Romax simulation tools allow the complete gearbox system
ing of these gearboxes since 2008. The final iteration of the test to be analyzed in a fully coupled 6-DOF environment, including
program was Gearbox 3 (GB3), which was tested in late 2016. the mechanics and stiffness of gears, bearings, housings, shafts,
planet carriers and supporting structures. This allows the predic-
tion of misalignment of the gears and bearings, which is one of
the key inputs that affect the durability of these components.
Figure 3 RomaxWind analysis model of GB3, including NREL 2.5 MW

Figure 1 As the wind industry seeks to reduce costs, improvements in dynamometer shafting and NTL system.
gearbox reliability will improve the bottom line.
The test article was heavily instrumented with strain gauges
The 2.5 MW dynamometer at the NREL National Wind on the ring gear both internally and externally, strain gauges on
Technology Center allows for accurate replication of field con- the planet bearing inner rings, and proximity sensors to mea-
ditions encountered by wind turbines such as transient load- sure carrier alignment to the housing as well as housing align-
ing, rotor off-axis non-torque loads (NTL), and grid interface ment to the bedplate. The strain gauges placed within the planet
conditions. Romax carried out an engineering assessment of bearings (a pair of tapered roller bearings with the outer races
the GB3 test article, focusing on the planetary stage modelling, integral to the gear blank) were of particular interest, as this is
instrumentation, gearbox assembly, and data analysis. rarely done. Ten gauges were bonded to the inner races of the
The gearbox was fully modeled in RomaxWind as part of the bearings (both upwind and downwind) in custom machined
design effort. RomaxWind is a drivetrain system modeling tool grooves. This allowed for the analysis of the variation of the
developed over the last twenty years for wide usage in the rotat- load zone during testing, and correlation with RomaxWind pre-
ing machinery industry, particularly in wind turbine gearbox dictions created in the design phase of the project.

increases in planet bearing reliability are realized.
This more rigid arrangement allows for better load share
between the upwind and downwind bearings, which in turn
leads to increased L10 life, as predicted in RomaxWind analysis.
It is this combination of advanced analysis tools yielding
insight to the design process, backed by innovative testing to
confirm these assumptions, that is closing the gap between
design-estimated and actual wind turbine gearbox field reli-
ability. Knowledge gained from the Drivetrain Reliability
Figure 3 Instrumentation Layout. Collaborative is publicly available to facilitate reliability
improvements, and ultimately result in improved gearbox
design standards and practices.
Romax Technology, Inc.
Phone: (970) 397-5253
www.romaxtech.com
Travis Histed Chad Glinsky

is an engineering graduated from
Figure 4 Experimental Results 100% torque (360 kNm), no NTL. analyst at Michigan State
Romax and is University with
responsible a master of
for delivering science degree
project work in mechanical
and assisting engineering.
customers with solutions. Having His research experience is
joined Romax in 2014, Travis’ prior in drivetrain dynamics and
experience includes hydro-turbine controls of continuously
analysis and design, natural gas variable transmissions. Prior
engine fuel delivery systems, industry experience includes
and manganese mining in South automotive quality engineering,
America before joining Romax in electromechanical design, and
2014. He graduated from Colorado noise and vibration testing.
State University in 2011 with a He joined Romax in 2012 as an
degree in mechanical engineering. engineering analyst and is now the
Figure 5 RomaxWind Prediction 100% torque (360 kNm), no NTL.
Engineering Manager for the US.
As can be seen by comparing the experimental results with

RomaxWind analysis, load zones are shifted 20 degrees between For Related Articles Search
the upwind bearing and the downwind bearing rows as a result
of the tipping moment created by the axial thrust generated wind turbines
from the helix angle on the planetary gear set. at www.geartechnology.com
By employing this more rigid pre-loaded TRB pair in each

planet of GB3, compared to the more traditional double row
cylindrical bearings used in the predecessor gearbox GB2, great
Figure 6 Planetary bearing L10 life predictions show improved life

for GB3 planet bearings as a result of improved load share
between the upwind and downwind row. This is a result of the
increased rigidity of the pre-loaded TRB pair, compared to the
more traditional double row cylindrical roller employed in GB2.

feature
Testing 1,2,3…
What’s New and Noteworthy in
Software Applications in 2017?
Matthew Jaster, Senior Editor
In general, people have a love/

hate relationship with the term
“update.” We certainly don’t appreci-
ate updating our smartphones since they
potentially cause more problems with each
new download. Software can also have its
fair share of frustrations, but it can also be
an extremely valuable tool if the updates
and new product developments make
your job easier. Each year, developers like
KISSsoft, GWJ Technology and MESYS
offer software tools and consulting services
for the gear industry. Some are brand new
products others are upgrades from previ-
ous software packages.
GWJ Updates eAssistant

Software
GWJ Technology GmbH is constant-
ly working on software enhancements
and adding new features to the system
in order to keep the applications up-
to-date. GWJ recently released a prod- Shaft calculation with GWJ Technology’s eAssistant software.
uct update for its web-based calcula-
tion software eAssistant. The new ver- metric system and the U.S. customary pled FE calculation of multi-shaft systems
sion comes with a variety of new fea- unit system. The user can quickly switch with gears as non-linear coupling ele-
tures and functions including a sig- between the units. There are several ments. SystemManager runs as a desktop
nificant improvement of the eAssis- more improvements in the software like application, making it possible to con-
tant framework. The software can now the addition of the ANSI/AGMA 2104- figure and calculate entire systems with
be launched independently of a web D04 standard to determine the load just a few mouse clicks. SystemManager
browser. There will be no more prob- capacity of cylindrical gears and plane- now allows the import of 3D housings
lems with pop-up blockers and browser tary gear trains or the implementation of as STEP files. The software meshes the
zoom. Additionally, all calculation mod- gear qualities according to DIN 58405, parts automatically to consider deforma-
ules now include two unit systems: the ISO 1328 and ANSI/AGMA 2015. tion and stiffness of the housing through-
Fu r t he r more, out the system. A further extension of the
GWJ has some 3D elastic parts function is the support
new develop- of planet carriers and imported shafts.
ments with Planet carriers can be imported as CAD
SystemManager. models or be defined parametrically; var-
System Manager ious basic designs are available for the
is a true soft- parametric planet carriers.
ware application For more information:
for complete sys- GWJ Technology GmbH
tems of machine Phone: +49 (0) 531-129 399 0
www.gwj.de
elements, i.e., the
software is a cou-
Gearbox with Housing with GWJ Technology’s SystemManager software.

KISSsoft Launches 03/2017 at Hannover Messe
The new version of KISSsoft 03/2017 was released during
Hannover 2017 with a number of innovations including:
• Reliability evaluation of gear units on system level
• Simplified modeling using predefined gear stages in KISSsys
• Calculation of root stresses with FE for cylindrical gears
• Variation calculation for the inner geometry of bearings
• Determination of the unbalance response during the vibra-
tion calculation of shafts Web demos inform users about
various subjects in the calculation programs KISSsoft and
KISSsys. Learn more about new developed features, about
sizing and optimization strategies, see examples and much
more; easily on your work desk. These web demos are free of
charge, all you need is 45 minutes to
get to know the various applications of
the software.
Additionally, KISSsoft USA is
now providing additional sup-
port through a YouTube chan-
nel (www.youtube.com/channel/
UCPk0PftMUVTfncY657Yr7Sw). The
videos are designed to help users with
questions about how the software
works and provide some basic engi-
neering knowledge related to gear
design. Over 20 videos are already
available for viewing and cover top-
ics such as general gear design, reverse
engineering, 2D & 3D export of gear
forms, shaft construction, contact
analysis and report customization.
KISSsoft USA LLC.
Phone: (815) 363-8823
www.kisssoft.com
MESYS
Integration of 3D-Elastic Parts into a
Shaft System Calculation
In calculations for shaft systems like
gearboxes the shaft are often considered
as one-dimensional elements for the cal-
culation of shaft strength, bearing life
and safety factors for gears. This has the
advantage of short calculation time and
easy consideration of boundary condi-
tions. An additional housing stiffness
can easily be added by using a stiffness
matrix which couples the stiffness at dif-
ferent support positions.
The MESYS shaft system calcula-
tion software allows the import of
3D-housings as STEP-files since 2016.
The software meshes the parts automati-
cally and generates the reduced stiffness
matrices which had to be calculated by
separate FEA calculations and then to be
imported before.

feature TESTING 1,2,3…
In version 04/2017 the integration shows a first natural frequency (an

of 3D-elastic parts in the MESYS shaft axial mode) of almost 22’000 1/min.
system calculation is further extended. Considering the elastic housing the first
3D-elastic housings can not only be con- natural frequency is a bending mode of
sidered in a static calculation, but also in about 15’200 1/min, which would lead to
the calculation of natural frequencies by problem for a planned operating speed
using a modal reduction. The influence of 15’000 1/min. Including the addi-
of housing elasticity on natural frequen- tional right support the natural frequen-
cies is much larger than on static defor- cies of the bending modes rise to 25’000
mations. 1/min, die first axial frequency falls to
For example a L-shaped spindle test 19’600. The imported CAD-model was
stand without the right support and the existing CAD-model for manufac-
without considering housing stiffness turing. This is not optimal because of
READY many holes and the bolts, but it still can

be used. In case the holes and bolts are
deleted in the CAD-model memory
usage and initial calculation time for the
calculation can be reduced.
A further extension is the support of
TO
3D-elastic planet carriers. Compared to
housings the planet carries rotate in the
system and therefore the calculation has
to cope with large rotations. The elastic
deformations of the planet carries have
an influence on the load distribution of
the gears and therefore should be con-
ROLL
sidered at design of tooth trace correc-
tions. The tilting of the planets will also
have an influence on the bearing loads
and the global torsional stiffness.
EXPANDING YOUR EXPECTATIONS

McInnes Rolled Rings continues to expand not only our facility,
but also your expectations of what responsive service should be.
We’re committed to the delivery of quality products with the
fastest shipping times in the industry.
Speed. Quality.
McInnes Rolled Rings.
1.800.569.1420 • 1533 E 12TH STREET • ERIE, PA 16511

www.McInnesRolledRings.com

Another possibility of an integration
of 3D-elastic parts in the shaft calcula-
tion is the option of 3D-elastic rotation
symmetric parts, which can be defined
using a polygon. These 3D-elastic parts
define an additional stiffness matrix. As
example a flex-pin is considered here.
In some older literature equations for
the deformations of a flex-pin are given
based on the Euler-Bernoulli-beam with-
out consideration of shear deformations.
In an example a beam model without
shear deformations shows a deflection
of 15 µm, including shear deformations
the deflection is 23 µm and in case of
usage of 3D-elastic parts the deflection
is 42 µm. The usage of a 3D-elastic parts
will lead to an increase by 80 percent
compared to a shear-elastic beam ele- Efficient gear cutting for
ment. The reason is the deformation complete machining
in the two interference fits where the
rigid connection of the beams is much
5-axis-turning center for all
too stiff. The 3D-elastic part is provid-
machining tasks
ing a better model for the deformations. Single clamping operation for
As the parts are taken into account like highest precision
welded in the calculation the real-life POWER SKIVING
deformation should still be a little larg-
er as there could be some sliding in the
interference fit.
The integration of 3D-elastic parts
into the shaft system calculation allows TURNING
to consider additional stiffness without
the need of external FEA programs. A
time-consuming and error-prone trans-
fer of stiffness matrices is therefore not
DRILLING
needed any more.
A full calculation in a FEA program
would allow more possibilities for defin-
ing boundary conditions and would
allow nonlinear calculation including MILLING
contact. The shaft system calculation t
footprin
based on one dimensional shafts has the
90 sq ft
main advantage of short calculation time
ss than
in range of seconds, which allows the Le
use of extensive load spectra and param- GRINDING
eter variations. With the integration of
3D-elastic parts these advantages are
preserved.
PITTLER PV315
The small footprint multi-talent
MESYS AG MEASURING
Phone: +41 44 4556800
www.mesys.ch Contact our US-Sales Team to learn more:
DVS Technology America Inc.
For Related Articles Search 734-656-2080 [email protected]
software
www.pittler.de

feature
Anatomy of a Rebuild
Nuttall Gear Taps Machine Tool Builders
for Shop Floor Upgrades
Matthew Jaster, Senior Editor
Infrastructure engineers contin- A Rich History in Gear ing, material handling, food and bev-
ually caution the U.S. govern- Manufacturing erage, textile, wastewater, cement and
ment about deteriorating bridg- Founded in 1887, Nuttall Gear, Niagara marine on applications such as pumps,
es and dams. According to Nuttall Falls, New York, developed and intro- fans, compressors, crushers, mixers,
Gear, the average age of the 609,380+ duced single helical gears, one of the conveyors, stacker/reclaimers, turbines,
bridges in the United States is nearly most significant contributions to the cranes, winches and propulsion equip-
42-years-old and the U.S. spends an field of gear engineering. Today, Nuttall ment.
average of $12 billion annually on repair/ specializes in providing complete cus-
replacement costs. tom packaged drive assemblies com- The Rebuild Strategy
For 60+ years, Nuttall Gear has pro- bining both mechanical and electrical Ken Flowers and Ron Peiffer at MTB
vided highly-engineered, long-lasting components to meet specific customer answer plenty of questions on a daily
gearbox solutions for the bridge market. requirements. basis. When you’re in the rebuild, refur-
It’s one of several key heavy industrial Nuttall designs and manufactures a bish and remanufacture business, it’s just
sectors that the company provides exten- variety of gearing solutions including one-step in a highly-detailed process.
sive application expertise and custom- vertical and horizontal drives, speed Can we automate this equipment? Is
ized solutions. reducers and speed increasers, cast iron there any life left in this machine? How
In order to accommodate these mar- and fabricated steel housings and flange can we make this gear hobber more pro-
kets, Nuttall Gear (an Altra Industrial mounted and scoop mounted gearmo- ductive? Bogdan at Nuttall Gear came
Motion Brand) relies on the latest tors. Nuttall can provide entire drive to MTB with his own list of questions
machine tool technology. This includes packages including reducer, motor prepped and ready to go.
upgrading and rebuilding some of the mounted on a bedplate with couplings, “Obviously cost is always going to fac-
equipment. coupling guards, backstops, chain and/or tor into your decision, but you’re also
“We had some pretty old machines belt drives, clutches, shoe or disc brakes looking at service and support, machine
on the floor that were manufactured in and auxiliary lubrication consoles. tool experience and any additional ideas
the late 1960s and early 1970s. It was Custom, heavy-duty Nuttall drives are and concepts MTB brought to the table.
tough to get service on the equipment utilized in a range of key markets includ- There’s a lot of back and forth between
and almost impossible to hunt down the ing metals, pulp & paper, mining, textile, both companies when you start discuss-
necessary replacement parts,” said Dan oil & gas applications such as extruders, ing what you want and what you need
Bogdan, senior manufacturing engineer crushers, elevators, water screens, bri- out of the rebuild,” Bogdan added.
at Nuttall Gear, a division of Altra. quetting machines, de-barkers, convey- After determining which machines
Instead of investing in all-new equip- ors, drawworks, recoilers/uncoilers and made the most sense for rebuild, the
ment, the company developed a rebuild dredges. Nuttall team created a strategic plan for
strategy. This centered on a compa- Nuttall acquired Delroyd Worm Gear the equipment, basically researching and
ny-wide initiative to have at least one in 1997. Delroyd was founded in 1923. documenting what features and capabili-
machine rebuilt each year depending on It is recognized worldwide for designing ties made the most sense.
business conditions. and manufacturing high quality, long- After choosing MTB to upgrade a gear
“We had recently purchased a brand lasting worm gear drives and unique, hobber, Nuttall Gear has commissioned
new Höfler gear grinding machine custom-engineered worm gear prod- the company to rebuild a worm gear hob-
and wanted to upgrade our hobbing ucts. The company offers a wide range ber and a thread milling machine. They
machines as well,” Bogdan said. “We of products and services including sin- plan to continue this in the near future
couldn’t justify purchasing brand new gle, double and triple worm and heli- by retrofitting a gear inspection machine
machines in this area, so we decided to cal worm reducers, custom-engineered and rebuilding an additional gear hobber.
see if we could upgrade/rebuild some of worm gear reducers, standard and spe- Here’s a closer look at some of the equip-
our core equipment to support existing cial worm gear sets, reverse-engineered ment that has been upgraded:
sales and future growth. Machine Tool gear sets and gearboxes and gearbox
Builders (MTB) sounded like a good rebuilding services.
option based on cost, experience and Delroyd drives are found in various
service and support.” key markets including power generation, rebuild
metals, pulp and paper, oil and gas, min- at www.geartechnology.com

Pfauter Turbo 900 Helical Gear ing the new pipes, valves, pumps, etc.,” tle bit different than other companies
Hobber (Rebuilt in 2012) Bogdan said. “These were quality parts. because the company does a great deal of
Before the upgrade, the 900 was a man- The machine is sturdier now and we custom work and makes all kinds of dif-
ual machine that was originally manu- have the option of using carbide hobs if ferent gearing. They are heavy into lean
factured in 1968 and incapable of cutting necessary.” manufacturing and prefer not to run too
a lead angle within required tolerances. Flowers and Peiffer continued to many parts at once and put them in stor-
The 900 was also no longer capable of answer questions and provide additional age. The company philosophy is to run
cutting a crown. Both of these condi- support after the project was completed. the parts as needed.
tions caused additional machining via For example, Bogdan said that the com- Nuttall Gear still makes fly tools for
offsets as well as additional shave and pany was recently running a part and worm wheels. Essentially this is when
grind time. wanted to perform a machining tech- you take a finishing tooth from a hob
Since Nuttall doesn’t typically run 20, nique known as opposite hand hobbing and use it to rough and finish the worm
30 or 40 pieces one after another, it was (Cutting a right hand gear with a left wheel in a single pass. The company
important that the setup time was quick- hand hob). wanted this worm gear hobber to be able
er and more efficient. “This is a fairly straightforward pro- to use tangential hobs, in-feed hobs and
“We need the machine to be able to cedure on a manual machine, but when fly tools. This requires long, tangential
set up a part and break it down, set up we tried to do it on the CNC machine, movement on the hobbing machine.
another part and break it down, etc. We it wasn’t working quite right. We made a “Side to side movement has to be
seldom run more than 2 or 3 of the same call to MTB and they were able to iden- much longer than a regular hobbing
part. This machine is typically used for tify what needed to be done in order to machine,” Bogdan said. “You can buy a
pinion shafts, different lengths and dif- perform the technique on an automatic brand new hobber and it will cut worm
ferent pitches, so we need to be able to machine,” Bogdan said. gears, helical gears, it will pretty much
setup and change-out very quickly, one cut everything. But anywhere I go for
job to the next.” Norton G&E TWG 40 Worm Gear a brand new gear hobber, you won’t
MTB converted the manual machine Hobber (Rebuilt in 2014) find the tangential movement needed if
to a CNC machine and it quickly became The rebuild strategy on the worm gear you’re using fly tools.”
Nuttall’s most efficient and reliable hobber was to upgrade a 1960s machine So this particular capability needed to
helical hobbing machine. Bogdan was that covered the smaller size worm gears be custom-made in the rebuild. Nuttall
pleased with the modifications MTB (going from a minimum center dis- required tangential and radial infeed
made. The upgrades led to improved tance of 2.5"–29". This included upgrad- hobbing. MTB provided both of these
lead times for both setup and machine ing the CNC controls, eliminating sev- capabilities.
cycle time. The crowning capability was eral hydraulic leaks that could not be MTB also took the helical software
restored, and the software was updated repaired by the maintenance staff and and adapted it for use to use on the
and more user-friendly. updating machine capabilities in order worm gear hobber. “There’s different ter-
“We were also very aware of the parts to improve setup and cycle times. minology and you’re using different lan-
that were used in the rebuild, includ- Bogdan said that Nuttall Gear is a lit- guage, so they added all the software to
make it easier to use and understand,”
Bogdan added.
Thanks to these upgrades, the worm
gear hobber boasted initial setup reduc-
tions greater than 50 percent (down
from 2+ hours to less than 1 hour) as
well as cycle time reductions between
40 and 60 percent. The gear quality and
surface finish were improved, controls
were updated to CNC and the rebuilt
hobbing head allowed for the use of car-
bide tooling thanks to the sturdier con-
struction of the rebuilt machine.
“We couldn’t consider carbide tooling
in the past thanks to the machine vibra-
tion,” Bogdan added. “Now we have the
option if needed and it gives us more
flexibility. With the redesign, we get bet-
ter quality parts, better finishes and we
can run parts much faster.”
MTB suggested transforming a hobbing machine
into a thread milling machine for Nuttall Gear.

feature ANATOMY OF A REBUILD
Pfauter 250H Horizontal Hobbing machine to do anything. Bogdan said correct size. MTB updated the software
Machine into a Thread Milling the time that this took with the manual so shorter trial cuts were now built in.
Machine (2015) machines was unacceptable and the old Cutting time improved 40 to 60 percent
This rebuild was a similar challenge. The machines (like the other examples) were with carbide cutters and 15 to 20 percent
company wanted to upgrade a thread very difficult to maintain regularly. And with standard cutters. Part setups were
milling machine that could provide fast- forget about finding replacement parts. significantly reduced.
er setups and easier changeovers. They With the rebuild, Nuttall Gear now
were still working with old machines had automatic indexing, the software Future Upgrades
from the 1940s and 1950s that had the was easier to use and the machine had While the purchase of the Höfler gear
same problems as some of the other the capability to use different size cut- grinding machine certainly opened up
older equipment. ters, interchangeable arbors, etc. It basi- new markets and new opportunities for
There was no machine head stability, cally gave the company the option of Nuttall Gear, the rebuilds and upgrades
for example. This prevented engineers doing a majority of parts in a single served an entirely different purpose.
from utilizing newer tooling and lower- machine. “Each of these upgrades simply
ing run times. Bogdan said they were “This flexibility gave us the opportu- enhanced and optimized the day-to-day
also interested in using insertable blade nity to get rid of a few machines on the business we already conduct in these
carbide cutters especially for bigger pitch shop floor. It replaces the work done on heavy industrial sectors,” Bogdan said.
parts since the older machines couldn’t two of our previous machines, almost “This is a cost-effective way to upgrade
take it due to the vibration. three in reality. We just keep the other your plant on a set budget and think out-
The game plan was to figure out the one around for very small sizes,” Bogdan side the box a little when you’re looking
main range of parts (pick the sweet spot) said. at the older equipment you’re still run-
and find out if MTB could upgrade The rebuild let Nuttall Gear utilize ning on the floor.”
one of the machines. As it turned out, carbide cutters that didn’t work quite Nuttall Gear still has its strategic
MTB had a Gleason horizontal hobbing as well on the older equipment. They rebuild plan in place. They plan to tar-
machine that fit all the criteria. MTB attempted to use carbide cutters on an get another gear hobber to rebuild in
told Bogdan that they could transform older, manual machine and blew the the near future as well as retrofit a Maag
the hobber into a CNC thread milling endcap off the back of the machine in SP-160 Gear Inspection Machine. These
machine by simply changing the cutting the process. “Couldn’t handle it until the upgrades will most likely occur between
head. machine upgrade,” he added. 2017 and 2018. The company will con-
“The platform and the base were per- The stability of the machine was one tinue to work with MTB on these and
fect, they simply needed to make a few of its greatest perks. By converting a additional projects.
simple machine conversions,” Bogdan hobbing machine into a thread mill, gear The markets Nuttall Gear specializes
said. engineers now had a stable, automated, in, particularly bridge drives, is starting
The upgrade offered significant machining cell at their fingertips. to pick-up according to Bogdan. “We
advantages. The old thread milling “With the old equipment, the oper- have a lot of quotes for bridge drives and
equipment was all manual. The opera- ator had to take a trial cut before the there’s still plenty of work available to
tor had to be standing in front of the first pass during part setup to establish upgrade some of this equipment. We’re
hopeful that there will be plenty of new
opportunities to test the gearboxes in
bridge drives and offer our services and
expertise.”
Bogdan also sees some more oppor-
tunities in transportation, particular-
ly light rail applications. “We’re getting
more work in subway systems as well as
some activity in oil and gas. When the
oil industry starts picking up, we’ll be
much busier and we’ll need to make sure
the equipment we’re using is up to speed.
Timing is everything in this business!”
Machine Tool Builders (MTB)
Phone: (815) 636-7502
www.machinetoolbuilders.com
Nuttall Gear
Phone: (716) 298-4100
Nuttall Gear now had automatic indexing, software www.nuttallgear.com
upgrades and the ability to utilize different size
cutters on the thread milling machine.

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profits for your company. in action firsthand.
Columbus, OH
October 24–26, 2017 Greater Columbus Convention Center
feature ANATOMY OF A REBUILD
The Rebuild/Remanufacture Checklist

With each rebuild project, Dan Bogdan, “You should take all of your own con- said. “Why not cover every possible out-
senior manufacturing engineer at Nuttall siderations as well as the rebuilder’s con- come right from the very beginning?”
Gear, a division of Altra, gains more siderations before going to corporate for
experience and learns more about the
rebuild process. Here’s a quick checklist
project approval,” Bogdan said.
#7 Phone a Friend
There’s always going to be some-
of things to consider when upgrading
your equipment: #5 Don’t Forget the Add-Ons
It’s rarely just about putting
a new cutting head in a machine or
thing you miss or something you might
need the machine to do down the road.
Service and support is vital for the suc-
#1 Know Exactly What You Want

From the Rebuild Up Front
It’s better to go to corporate with a num-
updating the controls. There are always
other expenses to consider includ-
ing new arbors, safety enclosures, soft-
cess of the rebuild. Bogdan states that
MTB typically follows-up on a question
or comment the very same day. “They
ber in mind for the total cost of the proj- ware upgrades, etc. “Think about every will get back to you as quick as they can
ect instead of coming back asking for aspect of the equipment and remember and determine what they can do on their
more money during the rebuild. “If you
miss certain elements in the planning
phase, it might cost your company an Bogdan at Nuttall Gear says it's important to
additional $10,000 to $20,000. You don’t document everything and make sure all parties
want to be halfway through the rebuild are on the same page prior to a rebuild.
and find out you need more money to
complete the project,” Bogdan said.
#2 Experience is Important
Machine Tool Builders (MTB),
located in Machesney Park, Illinois, pro-
vides top quality, reliable machine tool
solutions thanks to its highly-experi-
enced staff, innovative ideas and cus-
tomer service and support. Bogdan did
his research and had a pretty good idea
about the expertise MTB provided. “If
there’s familiarity and knowledge of the
machine and a thorough understand-
ing of what you want to accomplish, it
makes the entire process so much easier,”
he said.
#3 Walk and Talk

While initial rebuild discussions
begin over the phone or via e-mail, the
that many of the older machines don’t
have the safety features and automa-
tion capabilities that might be available
end to solve whatever problem you’re
having with the equipment. It’s nice to
know we can call them up immediately
real legwork is done right on the shop after the project is completed,” Bogdan with any technical issues or questions,”
floor. “Ken Flowers and Ron Peiffer said. “These are areas that will cost much Bogdan said.
at MTB didn’t just rattle off potential more money down the road. It’s better to
ideas for our project,” Bogdan said.
“They toured our facility, looked at all
our equipment, and learned all about
prepare for these expenses at the begin-
ning of the project.” #8 Communicate Early & Often
Bogdan believes this is just as
important at the beginning of the proj-
our machining processes before offering
some suggestions for the rebuild project.” #6 Get Complicated
When you’re testing parts on
the machine in question, it’s pointless
ect as the end. Keep the communication
line open with your rebuilder, let them
know what you might be looking for
#4 Outline and Document

Everything
Corporate has to approve the cost of the
to select the most common part you
typically produce. Bogdan suggests you
pick the part that is going to be the most
down the road and what machines you
might upgrade next. “This is the most
useful part of the entire process,” Bogdan
project and they never like surprises. challenging and use that for the testing said. “Keep talking about what you need
It’s in the best interest for both parties phase of the project. “If you select a part and what areas would benefit from addi-
to keep communication open with your that has given you the most headaches in tional upgrades. Conversations generate
rebuilder, make sure everyone is on the the past and it runs smoothly, you’ll be great ideas for the shop floor.”
same page and write everything down. much better off in the long run,” Bogdan

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Ground and Hobbed

Globoidal Worm Sets Email your question — along with your name,
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visiting geartechnology.com.
QUESTION
Are profile ground and hobbed, globoidal worm sets
better than multi-axis CNC-generated globoidal worm
gear sets for reduction of noise and vibration?
Expert response provided by Prof. Dr. Karsten Stahl. Aspects

of the question can be answered by applying the results from a research
project within the German Research Association for Power Transmissions Prof. Dr. Karsten Stahl
Engineering (FVA). Therefore, the noise and excitation characteristics of is Chair, Machine Elements,
worm gears have an exceedingly different noise and vibration behavior Mechanical Engineering, at
TUM. He leads and conducts
against cylindrical or bevel gears. Worm gears generally show a homoge- research in the area of
neous sound power level distribution within a frequency range of 50 Hz mechanical drive systems,
and 5 kHz, and can be characterized as broadband noise. with particular interest in
Reasons for this are the high sliding velocities and the running in effect investigating the load capacity,
efficiency and dynamics of all gears types.
of the worm wheel — usually made from soft material, like bronze.
Therefore the manufacturing method will play a secondary role regard-
ing the noise and vibration behavior.

technical
Twist Control Grinding (TCG)

Walter Graf
This paper introduces the latest process developments for the hard-finishing of gears, specifically in regard to controlling
the so-called flank twist. The purpose of twist control grinding (TCG) is to either eliminate twist, to introduce a counter-twist
on purpose, or to add a specific twist to counteract the deformation of gears under load. By controlling twist, the contact
bearing surfaces of meshing gear sets can be fully optimized, and therefore, the forces acting on the bearing surfaces can be
ideally distributed. This leads to more efficient gears, both in terms of power density and fuel consumption. Today, in terms
of grinding times, twist control grinding is on par with the standard continuous generating grinding which is well-established
in the industry. High volume TCG production of twist-free gears, or gears with a defined twist, is now standard production
practice at several automotive gearbox manufacturers.
(The statements and opinions contained herein are those of the

author and should not be construed as an official action or opin-
ion of the American Gear Manufacturers Association.
Introduction
This paper introduces the latest process developments for the
hard-finishing of gears, specifically in regard to controlling the
so-called flank twist, also known as bias. This paper only men-
tions twist control in reference to continuous generating grind-
ing. Flank twist also occurs in profile grinding of helical gears
with crowning. Demands on gears have always included the
reliable transmission of high torque and the need for increased
power density, low weight, and minimal noise emissions. Over
recent years, greater efficiency, lower fuel consumption, and
CO2 output have been added to the growing list of demands.
Figure 1 Legislation for CO2 reduction.
Emissions and fuel efficiency are becoming more stringent in
all major market regions such as the USA, Europe, and China is to either eliminate twist, to deliberately introduce a counter-
(Ref. 1; Fig. 1), and the car companies are facing huge techno- twist, or to add a specific twist to counteract the deformation of
logical and economic challenges to comply. These requirements gears under load. More often than not, twist has some negative
can only be met by improvements in all aspects of motor vehi- connotations attached. However, with TCG grinding the word
cles, and specifically to the powertrain, i.e., the engine and the “twist” should be seen in a positive light, as it allows gear design-
transmission. Additionally, research by Ford and Ricardo has ers to use this phenomenon to fine-tune the gear geometry.
shown that a reduction in fuel costs — via improved gearbox Furthermore, the process, as presented in this paper, allows sep-
design — costs only half as much as similar economies realized arate TCG on the left and right flank in the same grinding pass.
by improvements to the internal combustion engine. According By controlling twist the contact bearing patterns of meshing
to one of many studies (Ref. 2), weight reduction can contribute gear sets can be fully controlled and, therefore, the forces acting
a major share of the total fuel consumption reduction. Hence, on the bearing surfaces can be ideally distributed, which leads
modifying the flank twist by TCG allows modification to the to higher power density, more efficient transmission of power,
contact pattern of gear teeth, thus leading to higher power den- and an increased longevity of gears. The TCG method gives gear
sity and a reduction in the overall weight of gears in general design engineers a high degree of freedom to design gear flank
and, by extension, a weight reduction of the transmission itself. geometries to match the demands made on automotive gears
Furthermore, TCG-ground gears have shown noise reductions and to translate desired design features into an economical man-
in transmissions of 2 to 3 decibel (dB). ufacturing process.
Flank twist occurs as a matter of course when machining heli- TCG is an added feature of the well-established, continuous
cal gears that feature lead modifications such as crowning. This generating gear grinding process. In principle, the kinematics
phenomenon is brought about by the geometries and kinemat- of this process can be understood as a worm drive (Figs. 2 and
ics inherent in the continuous generating grinding of helical 3), with an additional abrasive machining process consisting of
gears. Incidentally, profile grinding with a single rib wheel will an infeed X, a vertical feed-rate Z, and a lateral shifting motion
also lead to flank twist, but this paper will focus on generating Y — all working together simultaneously. The main difference to
grinding only. Simply put, the purpose of twist control grinding the standard continuous generating is that the grinding worm
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.

Figure 2 Continuous generating grinding principle. Figure 3 Machine axis movements.
Figure 4 Flank twist. Figure 5 Crowning and changing center distance.
has to be modified across its width in terms of its pitch and/or sured at the nominal base cylinder of the gear. The base cylinder
its pressure angle. For this purpose the dressing unit (C4 axis) corresponds to the base circle and is the cylinder from which the
needs to be swiveled continuously as it moves laterally across the involute tooth surfaces are developed. When grinding the flank,
width of the grinding worm. depending on the helix angle and the direction of the stroke, the
tip and root of a tooth flank’s transverse section are not ground
Defining Grinding Twist simultaneously. Modifications in lead direction, such as crown-
Grinding twist is a continuous change of the profile angle (fHα) ing or end relief (Fig. 5), are generally created by changing the
of the gear flank over the full width (Fig. 4). As previously men- center distance (X-infeed) between the grinding worm and the
tioned, flank twist occurs as a matter of course when grind- workpiece axes during the grinding process.
ing lead-modified helical gears. The change in the profile angle The change of the center distance between the grinding worm
fHα occurs across the face width of the gear. Depending on and the gear is also relative to the nominal base cylinder. The
the amount of lead crowning, twist can be minimal and often tooth’s root and tip of a transverse section are ground at differ-
ignored, as the profile fHα measurement is taken only across the ent revolutions of the gear. The contact paths are visible as feed
transverse section in the middle of the lead (Fig. 4). For this rea- marks (Fig. 6), so that between the grinding of the root and
son the gear’s teeth are produced within specified tolerances, grinding of the tip, several revolutions of the gear to be ground
despite some residual flank twist. have occurred. In generating grinding, this twisting effect is
As Figure 4 illustrates, when grinding helical gears the contact exacerbated by a more pronounced crowning or end relief, or by
path between the grinding worm and the part’s tooth flank does a greater helix angle of the gear flank. Particularly in the case of
not run on the transverse section of the part. (The transverse end relief configurations, in which the center distance changes
section is a cross-section perpendicular to the gear axis). The radically over a relatively short distance, process-related tooth
required modification of the tooth trace is defined and mea- twist will occur.

technical
Controlling Grinding Twist

TCG grinding takes place on modern existing continuous gen-
erating gear grinding machines that possess the necessary kine-
matics to control twist. Modification to the gear’s base pitch can
serve to compensate for any resulting twist, or serve to create a
deliberately produced target twist. This modification is made
possible by changing the pitch and/or the pressure angle across
the width of the grinding worm (Fig. 8).
Figure 6 Crowning and profile angle.
Figure 8 Modification of the grinding worm.
To control the twist that occurs in continuous generating

grinding, a continuous change of the pressure angle on the
grinding worm (Fig. 8) must be introduced across the shifting
distance on the grinding worm width. This correction is only
possible by applying diagonal generation grinding, such that
the gear has a dedicated position on the width on the grind-
ing worm in line with the changes of the pressure angle and the
pitch across the grinding worm width. As mentioned previous-
ly, this can either occur by continuously changing the pressure
angle or the pitch across the width of the grinding worm. TCG
utilizes both modifications simultaneously, thus TCG can short-
en the distance of the diagonal grinding pass in comparison if
only one of the modifications were used at any one time. There
are also machine tool builders that use only either pressure angle
adjustments or pitch adjustment across the width of the thread-
ed wheel. However, using both adjustments simultaneously has
proven itself as the most effective TCG method in the automo-
tive industry.
Figure 7 Twist on opposing helix angles. Figure 9 shows a typical layout of the grinding worm which,
in this particular case, is divided into three distinct sec-
While grinding crowning and end relief, the center axis dis- tions — one for roughing and two for finishing. The narrow
tance changes during the grinding of the gear. Consequently, ramp sections, s _1 to s_4, that are located in between the individ-
during one grinding stroke, while crowning and/or end relief ual grinding sections, are not used and represent a safety area to
has been generated, the direction of the center distance has been ensure that the cycle start of finishing, for example, will not be
reversed. The resulting effect is that the tip on one side is in plus in a transitional area between the roughing and finishing stroke.
(+), and of the root on the opposite side is also in plus (+), cre-
ating the described flank twist effect (Fig. 7), which also shows Diamond Dressing of Grinding Wheel
this effect on opposing helix angles such as present on right- and TCG requires a double-taper diamond disc for the dressing of
left-hand gears. The measurements are always on one flank, in the grinding worm profile. Generating a defined tooth twist
three locations across the face width of the gear. requires part-specific dressing tools, which, at any one time,
dress only with one single flank due to the different geometries
used for the right- and left-hand flanks (Ref. 4). This, of course,
increases the overall dressing time, in comparison to conven-

tional grinding in which both flanks are dressed in the same
dressing stroke. In contrast to line dressing, profile dressing
involves a linear contact between the grinding worm and the
dressing tool, resulting in far shorter dressing times than line
dressing. For line dressing, a flexible universal diamond dress-
ing tool with defined radii dresses the profile of the grinding
worm by using the machine axes on a line-by-line basis (Ref. 5).
As there is only a point contact between the grinding worm and
the dressing tool, the dressing times required for line profiling
are relatively high. Line dressing is only relevant for prototyping
gears, and so will not be further addressed in this paper. In addi-
tion to modifications and corrections of the twist and the profile
angle, the profile dressing method also permits changes in pro-
file crowning. Using the same dressing tool, the TCG process
also allows separate profile crowning and flank twist corrections
on each individual flank. To generate varying pressure angles Figure 9 Grinding worm layout.
on the grinding worm, the tool is swiveled during the dressing
process using the machine’s C4 axis (Fig. 10). So-called profile
roll sets are available for outside diameter dressing or round-
ing off the tip of the grinding worm. These roll sets generate the
required tooth tip profile of the grinding worm after both grind-
ing worm flanks have been dressed.
Manufacturing Twist-Controlled Gears

An exemplary definition of twist-relevant data on a manufac-
turing drawing is shown (Fig. 11). In contrast to conventionally
ground gears, TCG-ground gears need a precise indication as to
the three measuring locations across the face width of the gear.
In the case of the gear shown in Figure 11, the locations where
the measurements have to be taken are as follows, starting from
the top of the gear: 2.75 mm, 10.75 mm, 18.75 mm, with angle
profile deviation (fHα) on the drive side being +10 µm at location
2.75, 0 at location 10.75, and –10 µm at location 18.75.
Figure 10 Dressing the grinding worm.
Figure 11 Exemplary definition of twist.

technical
Effects of Twist
In order to show why grind-
ing with a specified and
controlled twist is worth-
while to pursue, the con-
tact pattern of a gear wheel
has been examined more
closely (Ref. 6). A gear with
the natural twist resulting
from continuous generation
grinding (Fig. 12) and one
ground with TCG (Fig. 13)
have been ground for this
purpose. These gears have
both been paired separately
with the same mating gear,
which had been ground
with continuous generating
Figure 12 Gear ground with natural twist. grinding with a natural twist
(Fig. 14). The resulting, dif-
ferent contact patterns are
shown (Fig. 15). It can be
seen that the contact pattern
is less sloping in the pair-
ing variant with the applied
TCG. Furthermore, in this
pairing the contact pattern
is spread wider across both
tooth flanks. Due to this
wider contact pattern the
torque load of the gear pair
can be spread over a larger
flank surface area. For this
reason individual points of
the flank would be subject
to a lesser load which, cor-
respondingly, would lead to
an increased load-bearing
Figure 13 Gear ground with counter twist. capacity.
Figure 14 Mating gear ground with natural twist.

Figure 15 Contact patterns of mating gears.
Economic Considerations and Conclusion References

The direct integration of TCG into the conventional continuous 1. Lee, R. “The Race to GHG Regulatory Compliance,” FCA US LLC, CTI
Symposium May 2016, Novi, USA.
generating grinding process translates into minimal investment 2. Murphy, M. Transmission Technology Development, Drivers and Challenges,
costs if customers already have Reishauer continuous generating Auto Intelligence 2013.
gear grinding machines that feature a dressing unit with swivel 3. Koffler, C. and K. Rohde-Brandenburger. “On The Calculation of Fuel
capability. Furthermore, the diamond dressing tools remain the Savings through Lightweight Design in Automotive Life Cycle Assessment,”
The International Journal of Life Cycle Assessment, Publisher Springer
same as for many existing conventional processes. In addition, Professional, Location, Chap. #. Edition 1/2010.
the TCG process requires minimal additional operator training 4. Thyssen,W. Schleifschnecke, Profilierzahnrad und Verfahren zum u. a.
if the operators already have experience with standard continu- Profilieren der Schleifschnecke, 2007, Reishauer AG, DE 10 2004 057 596
ous generating grinding. Today, in terms of grinding cycle times, B404.06.2009, German Patent 2009.
5. Jankowski, R., 2007, Profiliermethoden zur Erzeugung modifizierter
twist control grinding is on par with the standard continuous Schleifschnecken, DE 197 06 867 B4 06.12.2007, Reishauer AG, German
generating grinding which is well established in the industry. Patent 2007.
The number of workpieces per dress is also on par with stan- 6. Röthlingshöfer, T. and K. Wesely. “Reishauer Twist Control Grinding — a
Summary for Practitioners,” Internal Document, Reishauer AG, 2014.
dard continuous generating grinding. The benefits gained from
controlling twist justify the small software investment and the
influence of additional wheel dressing time. Following inten- For Related Articles Search
sive research work and several years of industry application,
grinding
Twist Control Grinding technology has proven itself in the mar-
ketplace and has, in many cases, eliminated gear honing, often
thought to be the only method for large-scale twist-free hard
finishing of gears. High volume TCG production of twist-free
gears, or gears with a defined twist, is now standard produc- After completing his toolmaking
tion practice at several automotive transmission manufacturers. apprenticeship in 1974, Walter Graf
worked for ten years in tool and mold
The higher process costs over conventional gear grinding are making workshops. He subsequently he
outweighed by the benefits of the reduction in torque loss, the continued his studies in Australia and
increase in bearing capacity of TCG-ground gears, and higher the UK and was awarded a Bachelor
of Science Degree (Honors). In 1992,
resulting power density in transmissions. The main challenge he began as a Product Manager for
which is presently addressed for TCG is the user friendliness super-abrasive grinding and dressing tools at Winterthur
of setting up the machine. Setting up a TCG process, or making Technology Group, Switzerland, and before the purchase
corrections, must be simple and fast. of Winterthur by 3M in 2011, he held the position of Chief
Marketing Officer for the entire Winterthur Group. At 3M,
his role changed to Global Segment Leader for bonded
abrasives. Since January 2014, he holds the position
of Marketing Manager for gear grinding machines at
Reishauer AG, Switzerland.

technical
Surface Structure Shift for Ground

Bevel Gears
Sebastian Strunk
(The statements and opinions contained herein are those of the (Ref. 3). However, it is known that lapped gear sets show — at
author and should not be construed as an official action or opin- least at low loads — a lower excitation level at lower and higher
ion of the American Gear Manufacturers Association.) mesh harmonics.
Originally, the motions between tool and work gear are
Ground bevel and hypoid gears have a designed motion error derived from a rolling process of the work gear and the gener-
that defines parts of their NVH-behavior. Besides others, the ating gear. After the transformation of the rolling motion into
surface structure has an effect on the excitation behavior. This a five- or six-axis free form machine, the motions of the single
surface structure is defined by the hard finishing process. axes are basically third order functions with a dominating first
Grinding shows the advantage of high repeatability, defined order content. The coordinates for all axes are written into an
flank forms with closed-loop corrections, and subsequently axis position table that is read in by the machine controller of
very low reject rates. However, it is known that for example the free form machine.
lapped gear sets show, at least at low loads, a lower excitation The generation of a ground pinion is realized via the rolling
level, including the lower as well as the higher mesh harmonics. motion of a cup-shaped grinding wheel that follows a path given
The generation of a ground pinion is realized with a generating by the axis position table. Some excitations in ground gear sets are
motion of a cup-shaped grinding wheel that follows a path given caused by the production process itself. The machine follows each
by the axis position table. Machine motions itself in combina- line in this axis position table and interpolates between the lines.
tion with resulting machine vibrations, and imperfect grinding At low roll rates, a high number of lines are given in the axis posi-
wheel roundness during a standard grinding process can lead tion table, and the machine can follow these lines very accurately
to a distinct surface structure with facets parallel to the contact- because of the slow motions and their continuous functions. With
ing lines. These lines, including their waviness, are crossed while low roll rates the machine inertia also contributes to smooth tran-
the contacting zone passes along the path of contact and leads to sitions between the lines in the axis position table.
excitations when rolling the bevel gear set. The MicroPulse pro- At high roll rates, fewer lines are generated in the axis-posi-
cess (Refs. 1–2), as it is implemented at present, gives the possi- tion-table. The machine has to follow these lines at a higher
bility to influence each axis position in each line of the axis posi- speed while the grinding wheel RPM, determined from a given
tion table with small, predetermined or random amounts. The surface speed, remains the same. This results in fewer revolu-
presented development is a process which improves the excitations of the grinding wheel between the axis positions of the
tion behavior of a ground bevel gear set by altering the surface part program, creating surface pattern similar to generating
structure of a generated member along the path of contact from flats. The minimal time increment between two axis positions is
slot to slot. This process can include the use of the MicroPulse limited by the controller-specific block time, which presents the
motions, but it is not required. Rather than using the same axis- upper limit of axis positions for each given roll rate. An addi-
position-table for every ground slot — the current state of the tional cause of certain surface pattern at high roll rates is the
art — every slot receives changes to its specific axis-position- degrading synchronization accuracy between the three linear
table. The changes from slot to slot are calculated to address the and two rotational axes.
objectionable harmonic excitation. For this reason the object- The above described effects can basically be summarized as
ed harmonic excitation is predictably addressable based on a influences where machine motion, in combination with result-
closed-loop iteration calibrating the chosen process parameters. ing machine vibration and imperfect grinding wheel roundness
during a standard grinding process, will lead to a distinct sur-
Introduction / State of the Art face structure with facets parallel to the contacting lines. These
Ground bevel and hypoid gears have a designed motion error lines, including their waviness, are crossed while rolling along
that defines parts of their NVH-behavior. In addition to other the path of contact and lead to excitations when rolling the bevel
dynamic effects, the surface structure has an effect on excita- gear set. Depending on roll rate and machine dynamics, these
tion behavior. This surface structure is defined via the hard fin- effects can be found at lower mesh harmonics (fast roll-rates) or
ishing process. The most common hard finishing processes are, at higher mesh harmonics (slow roll-rates).
for example, lapping, grinding, and skiving. Grinding shows the The MicroPulse process (Ref. 2), as implemented at pres-
advantage of high repeatability, defined flank forms with closed- ent, offers the possibility to influence each axis position in each
loop corrections, and, subsequently, has very low reject rates line of the axis position table with some small predetermined

Figure 1 Cooling fan with unequally spaced blades.
Figure 2 Tooth mesh surface structure and excitation change.
or random axis motion amount. In previous research (Ref. 2) next and lead to excitations of discrete harmonics that correlate
MicroPulse was used to introduce a predictable and/or random to the machined existing surface structure, including the sur-
surface structure on the flank to influence the NVH behavior of face waviness, leading to measured NVH-behaviors that are not
the ground gear set. In the standard grinding process the same acceptable in the final application of the ground gear sets.
axis-position-table is used for every tooth slot, leading to a simi-
lar appearance of the surface structure for every flank, if the Theoretical and Practical Background
process affected wear of the grinding wheel from the first to last The idea behind the “surface structure shift” was the develop-
slot is neglected. ment of a process that improves the excitation behavior of a
Additional literature research in the field of application and ground bevel gear set by altering the surface structure of a gen-
inventions utilizing principles of (frequency-) modulation in erated member from slot to slot. This process can include the
the field of mechanical engineering present the separation to use of the MicroPulse motions, but it can also be applied with-
the inventive idea. For example, in fans (U.S. 3006603 A) (Ref. out MicroPulse. Instead of using the same axis-position-table
4), torque converters (U.S.20110289909 A1) (Ref. 5), and tur- for every ground slot — today’s state of the art — every slot
bines (U.S. 1502903 A) (Ref. 6), an unequal spacing of the blades receives changes to its specific axis-position-table. The changes
leads to a changed excitation behavior. Figure 1 shows the exag- from slot to slot are calculated to address the objectionable har-
gerated example of a cooling fan with unequally spaced blades. monic excitation. For this reason, the objected harmonic excita-
The results of these spacing variations lower the peak harmon- tion is predictably addressable based on a closed-loop iteration
ics (e.g. — blade impact frequency of a fan) and introduce addi- calibrating the chosen process parameters.
tional sidebands. The energy of the peak harmonic is distribut- The following general cases (Fig. 2) are possible to change the
ed from the peak to the sidebands, leading to a lowering of the excitation behavior using this process:
peak harmonic. This idea applied to the spacing of gear teeth 1. Shifting the roll-positions so that not every facet (waviness)
has been part of several research projects, but showed only lim- is positioned the same way on each flank combined with a
ited success (Ref. 7). MicroPulse-motion.
The above stated properties of the standard grinding process 2. Shifting the roll-positions so that not every facet (waviness)
including the MicroPulse repeat precisely from one tooth to the is positioned the same way on each flank without additional
MicroPulse-motion.

technical
Figure 3 Simulated transmission error without any surface structure and waviness.
3. Changing the position of every facet (waviness) on every flank

only by applying the MicroPulse motions. The amplitude of the 6th mesh harmonic is pronounced,
4. Changing the distances of the roll angle increments in the axis which is not obvious in the analysis of the designed motion-
position table along a slot (from start-roll position to end-roll error. In this case the amplitude of the sixth mesh harmonic is
position) with and without a different function from slot to at 9.4 µrad. It is assumed that surface structure effects/waviness
slot. on the standard ground flank lead to the effects of a higher sixth
• Changing the position for every facet/waviness for every mesh harmonic. To trace back these effects, they are replicated
flank with the same amount of shift (every flank has the via simulation with a purposely introduced surface structure
same pattern, only shifted versus the original pattern), uti- (Fig. 6). Here the simulated transmission error does not only
lizing roll-position shift and/or MicroPulse. This change is consist of the designed motion error, but also of a surface struc-
targeted to counteract dynamic events during the grinding
ture with a pattern of six-grooves-per-motion error parabola.
process, leaving a surface without significant surface effects,
eliminating higher harmonic excitations. An FFT of the transmission error (Fig. 6) leads to the results in
Figure 7; Figure 7 shows the result of an FFT of a simulated SFT
The amount of roll-position shift in cases 1) and 2) is a result of a gear set, including an additional surface structure (waviness);
of a calculation based on: and due to that, an additional excitation of the sixth mesh har-
• An analysis of the results of a single flank test (SFT) of the monic, correlating to the measurement of the real gear set.
evaluated gear set. The simulation including the surface structure represents a
• An analysis of the original axis position table (within the part simple model leading to the wanted replication of the effects of
program) that would be used in a standard grinding process a higher sixth mesh harmonic measured during an SFT of the
for a particular part, especially the relation between the num-
real gear set.
ber of lines in the axis position table and the roll angle.
• An analysis of the existing contact pattern. The most efficient way to lower the amplified excitations in
Figure 7 would be the elimination or reduction of the effects that
The simulation in Figure 3 shows the transmission error take place during the standard grinding process itself. This is
caused by a designed motion error, without any surface struc- desirable, but the possibilities are generally limited by machine
ture influence. Desirable is a low transmission error lead- stiffness and dynamic behavior in the grinding process.
ing to a low excitation level,
by means of low motion error
amplitudes. Note that a certain
amount of crowning in profile
and face width direction of the
flanks is required in order to
maintain a good contact pat-
tern under high load situations.
Crowning is a deviation from
conjugate flank surfaces and
will cause correlating ampli-
tudes of motion error.
A fast Fourier transforma-
tion (FFT) of this transmis-
sion error (Fig. 3) leads to the
results in Figure 4. This figure
shows the most desired result
of an FFT of a single-flank test
(SFT) of a gear set showing
only an excitation due to the
designed motion error.
The FFT of an SFT of a mea-
sured real gear set (Fig. 5) shows
a different behavior than the
analysis of the theoretical gear
set (Fig. 3), especially in the
higher mesh harmonic range.
Figure 4 FFT of transmission error caused by designed motion error without any surface structure (waviness).

Figure 5 FFT of SFT of a real gear set (baseline) with high 6th mesh harmonic.
Figure 6 Simulation of transmission (motion) error — including anticipated surface structure (waviness) — leading to a high 6th mesh
harmonic excitation.
Other ways to change the excitation behavior are to change during grinding are independent of the roll rate and keep their
several parameters of the standard grinding process. One exam- frequency, then the resulting surface structures will become
ple is to grind with lower roll rates. If the machine vibrations finer. This will lead to a shift of the excitations from lower to
higher mesh harmonics.
Excitation problems can
always occur on both mem-
bers of the gear set. If one
member is already ground
in a certain quantity, then
counteractions can only be
applied to the other member.
A purposely introduced wav-
iness to offset the problems
of the opposite member (EP
20130006061) seems imprac-
tical — in bevel gear grinding
in particular — if this requires
dressing waviness in the grind-
ing wheel profile. The roll
motion in generated pinions
and gears and the plunging
motion in non-generated gears
will not allow certain grind-
ing wheel profile waves to be
transferred to the flank sur-
faces. The process, affected by
relative sliding between grind-
ing wheel profile and flank
surfaces, would wipe out sinu-
soidal or similar wave forms
Figure 7 FFT of transmission error, including waviness leading to increased amplitudes of 6th and 12th order with maxima, minima, and
mesh harmonics.

technical
inflection points. Therefore the inventive process does not use nationally defined standards. Spacing variations cause also neg-
modifications to the grinding wheel profile, but strictly uses ative side effects like low frequency rumbling, which is not the
machine motions (MicroPulse) and process parameters (roll- case in the inventive process.
positions) to introduce and alter surface structures, and is there- In case of a structure shift, only the surface structure is
fore limited to the generated member. addressed in a defined way. Depending on the case, the surface
The theoretical idea is to change and improve the excitation structure in the entire generated flank area is positioned differ-
behavior by changing the position of the surface structure (wav- ently, e.g. — from slot to slot. In all cases this is done via roll-
iness) on each flank (structure shift), which is fundamentally position-shifts and/or roll-increment-changes and/or via utiliz-
different from the ideas of unequal tooth spacing that are refer- ing the MicroPulse motions.
enced as state of the art. A change of the spacing in a defined or Case 1. To change and improve the excitation behavior, the
random way will lower the gear quality according to the inter- following steps are applied according to Case 1), which utilizes
Figure 8 FFT of transmission error with MicroPulse leading to increased amplitude of 10th and 11th order mesh harmonics.
Figure 9 Theoretical effect of MicroPulse on surface structure, leading to an excitation of 10th and 11th order mesh harmonic
(here N = 5).

MicroPulse motions and a predetermined change of the roll 1 µm to alter the X axis motions. This axis moves the grinding
positions per slot. wheel almost perpendicular into the flank surface.
The objected harmonic is identified via an SFT or similar test The SFT of the newly ground part rolling with the master
(Fig. 5), possibly using a master gear for the uninfluenced mem- gear delivers a distinctly higher excitation of a certain harmonic
ber. In this example the sixth mesh harmonic is the objected (Fig. 8).
harmonic. Based on the artificially excited harmonic (Fig. 8), a corre-
The iteration process is started to identify the correct lation can be established between the division-factor N of the
MicroPulse parameters and to correlate them to the objected MicroPulse and the introduced surface structure, leading to a
mesh harmonic. In a first grind of the generated member, the distinct higher harmonic (Fig. 9).
MicroPulse division-factor (parameter) N is chosen via edu- In this case the chosen division-factor of N = 5 leads to a high-
cated guess. The amplitude A is chosen within the range of one er 10th and 11th mesh harmonic.
Figure 10 Theoretical effect of MicroPulse on surface structure with iterated and correct parameter N; predicted to lead to an
excitation of the 6th mesh harmonic (here N = 8).
Figure 11 Measured FFT of real SFT with higher 6th mesh harmonic due to MicroPulse.

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Figure 12 Measured FFT of real SFT with higher 6th mesh harmonic (8.8 µrad) due to MicroPulse with N = 8 and A = 0.2 µm.
With this correlated MicroPulse parameter N

the new correct parameter N* is calculated via
simulation of the MicroPulse process (Fig. 10),
which leads to an excitation of the object-
ed mesh harmonic (Fig. 11). If required, after
having the part ground with the new param-
eters, additional iterations must be conducted to
address the objected mesh harmonic. This leads
to the correct final parameter N.
The amplitude A of MicroPulse is lowered to
an amount where the influence is still measur-
able and influencing the objected harmonic.
The amounts will be in the lower tenth of a
micron range (Fig. 12).
The shift of the pattern from flank to flank is
calculated via the following procedure:
The amount of roll angle per line (RAPL) of Figure 13 New start roll-positions for every slot with NR = N – 1 (here N = 8).
the original axis-position-table is calculated:
(Toe – roll – position) – (Heel – roll – position) (1) with,
RAPL = As = NR * RAPL (3)
Number of lines in axis – position – table
with,
The parameters triggering the shifted surface structure coun- NR = N – 1 (4)
teract the effects of the original surface structure, and are calcu- This formula will lead to a shift utilizing the maximal amount
lated from the MicroPulse parameters. To calculate the correlat- of amplitude. This means that when organizing the shift via one
ing shift in the roll-position for every slot (ΔRPj) to change the sine-wave, patterns that are maximally shifted will theoretically
surface structure from slot to slot, the previously determined line up with the original non-shifted surface structure.
division-factor N of MicroPulse is utilized. The shift-amplitude- Alternatively
factor NR is calculated for a shift that is organized via a sine NR = N – (1 + 0.1 * N) (5)
function:
ΔRPj = i + 1 = As * sin [( 2 * π
z ) ]
1
* i
(2) This will lower the maximal amount of utilized shift-ampli-
tude so that, theoretically, no alignments with the original struc-
ture will occur.

The shift-amplitude-factor in this case correlates to
MicroPulse parameter N but can also be a factor calculated and
chosen in a different way.
The shift-amplitude As is calculated via this formula:
As = NR * RAPL (6)
To calculate the amount and distribution of shift of the roll-
position for each slot (ΔRPj), a single sine-wave is utilized.
ΔRPj = i + 1 = As * sin [( 2 * π
z ) ]
1
* i
(7)
with i going from 0 to (z 1–1) and with z 1

being the number of teeth of the part.
The newly calculated ΔRPj are added to the
toe-(dwell) and heel-(dwell)-roll-positions for
every slot, whereas the slot number j = 1 has
the untouched baseline roll-positions, thus
leading to changed roll-positions (Figs. 13 and
14).
Also, other shift-patterns are possible; for
example, a linear shift with a manually cho-
sen amount of shift for every slot; the center
of roll is not changed.
This leads to a pattern-shift Δφi for every
flank. Figure 15 shows the pattern shift for
Figure 14 New start roll-positions for every slot with NR = N – (1 + 0.1 * N) (here N = 8).
Figure 15 Relative position of patterns on flanks in regard to the new roll-positions for every slot (here N = 8, A = 1 µm).

technical
Figure 16 Simulation of transmission (motion) error, including anticipated surface structure.
three flanks using NR = N − 1. For better

visibility, the amplitude is chosen with
A = 1 µm.
Applying the pattern shift to the sim-
ulation of the transmission error results
in the surface structure shown (Fig. 16);
every flank shows a differing position of
the surface structure, leading to the sim-
ulated FFT of SFT (Fig. 17).
The comparison of the simula-
tion with introduced surface structure
and no shift (Fig. 7) — with the shifted
surface structure (Fig. 17) — is shown
(Fig. 18). The red graph shows the orig-
inal non-shifted FFT of the simulat-
ed SFT (Fig. 7), whereas the blue graph
shows the FFT of the SFT of the shifted
surface structure.
By applying factors for the surface
structure shift that were gleaned — via
simulation to real-world grinding pro-
cess — we learn that this approach leads
to a following of actual-measured FFT
of SFT (Fig. 19), and can be compared
Figure 17 FFT of transmission error, including introduced surface structure with shift of
structure from flank to flank, leading to lowered peak harmonics and to introduction of to the results of the original FFT of the
sidebands around 6th- and 12th-order mesh harmonics. baseline SFT (Fig. 5). The 6th mesh har-
monic amounts to 1.4 µrad; maximal
amount of the sidebands is 4.5 µrad.
Case 2. In this case, only a roll-posi-
tion-shift is utilized without any addi-
tional micro-motions via MicroPulse.
Facets at high roll rates can correlate
to the lines in the axis-position-table
and to the excited mesh harmonics.
To improve and change the excitation
behavior in these situations, the already-
existing surface structure is shifted on
the flank surface.
The shift-amplitude ASR in roll-posi-
tion for every slot is calculated via this
formula:
ΔRPj = i + 1 = ASR * sin [( 2 * π
z ) ]
1
* i
(8)
with,
ASR = RAPL and i going from 0 to (z1–1)
and with z1 being the number of
teeth of the part.
Figure 20 shows the FFT of SFT using
unmodified roll-positions, and Figure
Figure 18 Comparison of FFT of transmission error, including introduced surface structure with (blue) 21 shows the FFT of SFT using modified
and without (red, Fig. 7) shift of structure from flank to flank, leading to lowered peak roll-positions.
harmonics and introduction of sidebands around 6th- and 12th-order mesh harmonics.

Figure 19 Measured FFT of real SFT with introduced and shifted surface structure via MicroPulse (N = 8, A = 0.2 µm).
Figure 20 Measured FFT of real SFT with ground at a roll-rate of 20°/s without any roll position-shift.

technical
Figure 21 Measured FFT of real SFT with ground at a roll-rate of 20°/s with roll-position-shift.
Visible are the high peak harmonics in the area of 7th to 8th Discussion and Future Work
mesh harmonic, as well as in the area of the 14th to 16th mesh Today, basic calculation tools for the “surface structure shift” are
harmonic. used to optimize gear sets, starting with an educated guess, cal-
Visible is the lowering of peak harmonics in the area of 7th culation of the addressed mesh harmonic, and a guided optimi-
to 8th mesh harmonic as well as in the area of the 14th to 16th zation, as shown in this paper.
mesh harmonic. An alternative to the iteration process could be to calcu-
The 10th and 11th mesh harmonic were identified as late the exact division-factor N via the theoretical analysis of
machine-introduced harmonics. the contact pattern — assuming that theoretical and practical
Case 3. In this case only the MicroPulse motions are utilized contact have a high correlation for the objected gear set. This
to introduce and alter the position of the facets on each flank. means that if the objected gear set is far away from the origi-
Patterns can only be realized if the resolution of the axis posi- nal design, a “fresh” development or a reverse engineering via
tion table is sufficient. CMM to obtain the actual TCA is required. The first and last
Case 4. In this case, the distances of the roll angle increments roll positions for the beginning and end of the contacting area
in the axis position table along a slot (from start-roll position to at low load are obtained via analytical tooth contact analysis,
end-roll position) are changed with or without a different func- e.g. — Unical.
tion (for example, sine-function) for every slot. This process can The existing surface structure within this roll angle has a
also include additional MicroPulse axis movements. certain pattern, based on the SFT result, which is then repli-
Case 5. Changing the position for every facet/waviness for cated with the correct choice of the division factor N of the
every flank with the same amount of shift (every flank has the MicroPulse process. This should be done via simulation tools
same pattern, only shifted versus the original pattern) utilizing leading, e.g., to a MicroPulse pattern with six peaks within the
roll position shift and/or MicroPulse. This change is targeted to contacting area.
counteract dynamic effects during the grinding process. In addition, future developments regarding the surface struc-
ture should focus not only on generated, but also on the non-
generated members.
The tool of the “surface structure shift” is relatively new and

needs further investigation and practical studies. This should
include testing not only of gear sets on the test rig, but also end-
of-line tests as well as vehicle testing.
Get the
Conclusion Royal Treatment
• The results show that there is an effect of the “surface struc-
ture shift” as a tool to address a targeted reduction of excita-
tion of higher harmonics in ground bevel gear sets.
• The theoretical background of “surface structure shift” and
MicroPulse are explained at the beginning of this paper. After
this, several cases are shown, on how to influence the sur-
face structure with these tools. The two most relevant cases
are explained in detail. Case 1 utilizes additional machine
motions (MicroPulse) to influence the surface structure on
the generated ground bevel gear flank surface, in combina-
tion with the “surface structure shift,” predictably altering the
surface structure from flank to flank. This leads, as shown via
practical example, to the capability of lowering higher mesh
harmonic excitations while introducing sidebands.
• Case 2 only uses the surface structure shift, without additional
machine motions, and is preferably used under high-speed
machine motions, leading to an improved higher mesh har-
monic behavior.
• In general, the processes presented here aim at predictably
introducing more sidebands while lowering higher mesh har-
monic peak amplitudes. Stop being a servant to the search
References bar — www.geartechnology.com
1. Stadtfeld, H. J. and U. Gaiser. Method of Finishing Bevel Gears to Produce a
Diffuse Surface Structure, U.S. Patent US 7462092 B2, 2007. is a website fit for a king or queen:
2. Stadtfeld, H. J. “MicroPulse – Structure Grinding,” 2007, The Gleason Works
Publishing, Rochester, New York.
3. Stadtfeld, H. J. “The Science of Gear Engineering and Modern
• Complete archive of articles on
Manufacturing Methods for Angular Transmissions,” 2014, The Gleason
Works Publishing, Rochester, New York.
gears and gear components
4. Caruso, W. J. and B.M. Wundt. Turbo-Machine Blade Spacing with
Modulated Pitch, U.S. Patent US 3006603 A, 1961. • Directory of suppliers of gears
5. Marathe, B. Torque Converter with Asymmetric Blade Spacing, U.S. Patent
Application US 20110289909 A1, 2011. • Product and Industry News
6. Campbell, W. 1924, Steam-Turbine Rotor and Method of Avoiding Wave
Phenomena Therein, US Patent US 1502903 A. updated daily
7. Strunk, S. 2015, “Gezielte Erzeugung von Oberflächenstrukturen und
Nutzung von Modulationsprinzipien zur Optimierung des Verhaltens
geschliffener Kegelradgetriebe,” 2015, M.S. thesis, FG KFT, TU Ilmenau,
• Exclusive online content in our
Germany. e-mail newsletters
• The Gear Technology Blog
• Calendar of upcoming events
bevel gears
at www.geartechnology.com • Comprehensive search feature
helps you find what you’re
Sebastian Strunk, upon completing an
apprentinceship as automotive mechatronic looking for
technician at Mercedes-Benz in Bremen,
Germany, began his bachelor studies in automotive
engineering at Ilmenau University of Technology
in 2009. He completed his Bachelor thesis,
i.e. — efficiency improvements of newly designed,
automatic transmissions — during an internship
in the R&D department of Mercedes-Benz in Stuttgart, Germany in
2013. His passion for transmissions and gears prompted him to apply
for an internship at The Gleason Works in Rochester, New York.
The intership began in April, 2014, during which time he wrote his
Master Thesis about the roll-optimization of ground bevel gears. After
finishing both his thesis and a brief stint working in Ludwigsburg,
Germany for Gleason-Pfauter, Strunk in late 2015 returned to the U.S.
to begin work in the R&D department of The Gleason Works.

technical
Designing Very Strong Gear Teeth

by Means of High Pressure Angles
Rick Miller
The purpose of this paper is to present a method of designing and specifying gear teeth with much higher bending and
surface contact strength (reduced bending and surface contact stresses). The primary means of achieving this is by
specifying gear teeth with significantly higher pressure angles. This paper will show calculation procedures, mathematical
solutions, and the theoretical background and equations to do this. The required user input factors for the method described
in this paper are: numbers of teeth, pinion and gear; diametral pitch; center distance; desired minimum top land, pinion
and gear; desired contact ratio; and maximum backlash. The desired pressure angle can then be entered and another value
re-entered to make comparisons. The output factors would be the outside diameters of the pinion and gear, and other gear
data, based on the entered pressure angle. In the past, higher pressure angle gears have not been commonly designed and
specified because of the relative difficulties involved in designing them and the lack of appropriate and easy-to-use tools to
evaluate them. This paper contributes to making it easier to accomplish this task.
(The statements and opinions contained herein are those of the gear teeth and gear tooth data of various different pressure
author and should not be construed as an official action or opin- angles can be calculated, compared and evaluated quickly and
ion of the American Gear Manufacturers Association.) easily, and high pressure angle gears can be designed and speci-
fied. Gears can be designed based on desired top lands, contact
Introduction and Background ratio, and hob tip radius.
By convention, commonality of cutting tools, and familiarity,
several pressure angle choices have become industry standards Discussion
for gear designs. These include 14.5, 20, 22.5 and 25° pressure As stated above, two of the primary attributes of high pressure
angles. Twenty and 25° pressure angle gears are typically the angle gears that are potentially limiting factors and therefore
most commonly used today, although pressure angles as high as must be considered, calculated, and accounted for are: 1) circu-
28° to 30° have been used on occasion for maximum-strength lar tooth thickness at the outside diameter of the gear (top land
applications. thickness); and 2) hob tip radius and the resulting generated
Higher pressure angle designs were typically not considered or tooth root fillet radius; both of these are considered — each in a
used because of the limitations listed above, the most significant separate section.
being reduced gear teeth top lands and fillet radius. Standard In this report four separate gear tooth pairs are evaluated and
gear tooth proportions and universal rack geometry are based described:
on the pressure angles listed above and do not lend themselves 1. Traditionally designed gearset with 25° pressure angle serving
to designing gears with pressure angles above around 30°. as reference design
For higher pressure angle gear designs, numbers of teeth and 2. High pressure angle gearset with hob tip radius of zero and
other gear tooth macro-geometry items must be considered 36° pressure angle
3. High pressure angle gearset with a 0.007 inch hob tip radius
carefully so that the natural limitations of high pressure angle
and 35° pressure angle
gearing are avoided while exploiting their benefits. 4. High pressure angle gearset with a 0.020 inch hob tip radius
If not carefully designed, manufacturing the gears can be dif- and 33.5° pressure angle
ficult and more expensive. Gear cutting tools will usually be non-
standard. Gear noise will usually be higher due to the decreased To ease in the evaluation and comparison, and to isolate the
contact ratio and reduced root/tip clearance, which can entrap oil. pressure angle influence on the results so that pressure angle is
Separating force from the gear teeth increases directly with the main variable, the following inputs remain the same for both
the tangent of the pressure angle. In parallel shaft assemblies, the traditional 25° pressure angle design and the high (maxi-
this needs to be considered, as the increased forces arising from mized) pressure angle design:
high pressure angle gears may unacceptably shorten shaft or Numbers of gear and pinion teeth; diametral pitch; center dis-
bearing life. In planetary gearboxes, the net separating force is tance (standard center distance); the circular tooth thickness of
theoretically zero: the sun/planet separating force is canceled out pinion and gear for the high pressure angle gears is equal and
by the planet/ring separating force. Therefore, planetary appli- is set by the backlash. The 25° pressure angle reference design
cations offer an excellent opportunity to utilize higher pressure uses 15% long addendum pinion and 15% short addendum gear
angle gear teeth. tooth proportions and the resulting gear tooth circular tooth
The advantage of the methods described in this paper is that thicknesses to provide close to equal bending stresses for the

pinion and gear. This represents a typical relatively standard value and substitute Equation 1 (above). Because the Do term
gear design. appears in the denominator as well as being the unknown vari-
Program user inputs able solved for, the denominator value is set to the standard Do
• Number of teeth, pinion and gear: z1, z2 value. Because the contribution of this term is small, the poten-
• Diametral pitch: Pd tial “error” that this causes is negligible to the end calculation.
• Center distance (default = standard): a Calculate the outside diameter Do for both pinion and gear from
• Desired minimum top land, pinion and gear: ToP, ToG Equation 1.
• Desired contact ratio: mc Next, substitute the Do values calculated from Equation 1 into
• Maximum backlash: B
Equation 2, and calculate the contact ratio at that pressure angle.
Summary of user inputs for example of high pressure angle Iterate the pressure angle and calculate using Equations 1 and
gear set run 2 to converge on the desired contact ratio that was input. The
• 16 tooth pinion, 29 tooth gear result is the pressure angle necessary to achieve the desired con-
• 6 diametral pitch tact ratio, top land, and also meet other input conditions.
• 3.75 inch center distance (standard)
• Desired minimum top land, pinion and gear: 0.030 inch Derivation of Equations
• Desired contact ratio: 1.15 Outside diameter. Since top land is known by user input and
• Maximum backlash: 0.0120 inch
circular tooth thickness s is known by calculation from inputs or
Definition of terms (Note: Subscripts P = pinion; G = gear, as a separate input, Equation 3 can be solved for Do:
where necessary.) (3)
z1, z2 = Number of teeth (
to = Do s + inv ϕ – inv ϕo
d )
DbP = Base diameter, pinion
DbG = Base diameter, gear Solve Equation 3 for inv ϕo:
Pd = Diametral pitch t (4)
DoP = Outside diameter, pinion inv ϕ = s – o + inv ϕ
d Do
DoG = Outside diameter, gear
d = Pitch diameter The involute function is inv ϕ = tan ϕ – ϕ radians. If the
to = Circular tooth thickness at outside diameter (or any numeric value of inv ϕ is known and the angle is desired, this
known diameter)
contains a transcendental term, and the solution must be iter-
a = Center distance
ated using the Newton method; the result is called “ARCINV.”
pb = Base pitch
Look up or solve for the angle of the ARCINV.
DR = Root diameter
(5)
Z = Length of line of action
mc = Contact ratio
( )
cos ϕo = d cos ϕ
Do
(6)
ϕ = Pressure angle ... D = ( d cos ϕ )
ϕo = Pressure angle at outside diameter (or any known
o
cos ϕ o
diameter)
s = Circular tooth thickness at standard pitch diameter Substituting Equation 4 into Equation 6:
d cos ϕ (7)
Do =
Calculations for pressure angle corresponding to input top
land (tooth thickness at O.D.) and contact ratio, mc
(
cos arcinv (
s – to
d Do
+ inv ϕ ))
Contact ratio:
Mathematical solution:
d cos ϕ (1)
mc = ( Pz )
b
(8)
Do =
( d Do(t
cos arcinv s – o + inv ϕ )) But Equation 9:
(9)
(
pb = π cos ϕ )
Mc =
Pd (√( D2 ) – ( D2 ) +√ (D2 ) – (D2 ) – a sin ϕ)
oP
2
bP
2
oG
2
bG
2 (2) Pd
π cos ϕ and Equation 10:

Standard gear equations used:
√( D2 ) – ( D2 ) +√ (D2 ) – ( D2 ) – a sin ϕ
2 2 2 2 (10)
Z = oP bP oG bG
d = z
Pd
Db = d cos ϕ Combining Equations 8, 9 and 10 gives:
pb = (π cos ϕ)
Pd
mc =
Pd(√( D2 ) – ( D2 ) +√ (D2 ) – ( D2 ) – a sin ϕ)
oP
2
bP
2
oG
2
bG
2 (11)
s = π – B π cos ϕ
2Pd 2
Any other pressure angle can be entered and another value re-
Calculation procedure. Using input information and stan- entered to make comparisons.
dard gear equations above, calculate d, Db, and s for pinion and A spreadsheet or computer program can be created from the
gear. Since pressure angle is the unknown, create an initial trial equations and formulas included in this paper to automate the

technical
mathematical calculations.
As stated above, the result of this convergence routine shows
the pressure angle for the gearset above with the design input
values, considering the input value for top land thickness.
However, as also stated above, the second important consider-
ation is the hob tip radius and the root fillet radius it generates
for both the pinion and gear. The pressure angle for this con-
sideration is almost certainly different from the pressure angle
considering the pinion and gear top land only. So, in order for a
gear design to meet both design criteria (matching the top lands
and hob tip radius/tooth root fillet radius), the smaller of the two
pressure angle values must be used in the design of the gear teeth.
All gear data and stress calculations were performed using the
AGMA GRS 3.1.7 gear rating suite program. Due to the length of
the program data outputs, the data was summarized and shown
in a more abbreviated format.
Result of calculation for pressure angle from example from Figure 1 Hob tooth details.
top land consideration:
Pressure angle from top land input = 35°
Calculations for Pressure Angle Corresponding to

Input Hob Tip Radius Consideration
Mathematical solution. Program inputs in addition to the
inputs from the example above:
CSW = (circular space width of gear) which is also the circular
tooth thickness of the hob tooth
b = dedendum of gear (addendum of hob tooth)
r = (hob tip radius)
Summary of User Inputs for Example of High

Pressure
Angle Gearset Run for Hob Tip Radius Calculations
SW = 0.2663 inch
C
b = 0.1833 inch
r = 0.020 inch
(( sin ϕ
2 r
) – r + b) tan ϕ = CSW (12)
Figure 2 Hob tooth details for sharp corner (zero hob tip radius).
[ ]( )
1 – sin ϕ
r cos ϕ =
CSW
2
– b tan ϕ
(13)
input hob tip radius using Equation 15. Also, Equation 18 can
r =
[( CSW
2 )
– b tan ϕ] cos ϕ
(14) be used to find the pressure angle that matches a hob tip radius
of zero.
1 – sin ϕ Once a pressure angle is calculated for the desired hob tip
r =
[( )
CSW cos ϕ – b sin ϕ
2
(15) radius, enter this pressure angle into Equation 1 to determine
the outside diameters for the pinion and gear, and into Equation
1 – sin ϕ
2 to determine and calculate the new contact ratio — which
When r = 0: most likely will differ from the earlier input value. The remain-
numerator = ( CSW cos ϕ
2 ) – b sin ϕ = 0 ing gear data and stress analysis calculations can be performed
using these new values of pressure angle and outside diameters.
CSW cos ϕ = b sin ϕ (16) Result of calculation for pressure angle from example for hob
2 tip radius:
CSW (17) For this example we want to avoid a zero hob tip radius, and
tan ϕ =
2b we will set the hob tip radius to 0.020 inch and calculate the
pressure angle of the gear teeth that will produce this 0.020 inch
(
ϕ =tan–1
CSW
2b ) (18)
radius. A pressure angle of 33.5° is the calculated number, so a
33.5° pressure angle will be used for the further calculations of
This is the pressure angle for a hob tip radius of 0 (sharp corner). the remaining gear data and stress and rating analysis.
Calculation method: using the values for r, b, and CSW, iterate For a hob tip radius of zero (sharp corner), the pressure angle
the pressure angle and find the pressure angle that matches the for the gear teeth is 36°.

Figure 3 Spur gear specifications: 25° pressure angle.

technical
Figure 4 Spur gear stress analysis: 25° pressure angle.

Figure 5 Spur gear specifications: 33.5° pressure angle.

technical
Figure 6 Spur gear stress analysis: 33.5° pressure angle.


technical


technical

Figure 11 Reference 25 PA and 33.5 PA gear tooth profiles.
Figure 12 25° pressure angle gear teeth.

technical
Figure 13 33.5° pressure angle gear teeth.
Figure 14 35° pressure angle gear teeth.
Review of Results and Commentary addendum pinion and 15% short addendum gear tooth propor-
All gear trials were run with the following common gear data tions, and the resulting circular tooth thicknesses.
attributes: The first trial was for the 25° pressure angle design; this
• 6 DP, 3.75 inch center distance, serves as the benchmark. Following are the relevant results:
• 0.012 inch maximum backlash, • Bending stress, PSI, pinion/gear is 89,522/91,873; static torque
• 16,000 in-lb pinion torque, rating bending, (in-lb): 11,704/20,670
• 1 RPM pinion speed. • Surface contact stress, PSI, pinion and gear: 328,302; static
As stated above, the 25° pressure angle gearset uses 15% long torque rating surface P/G: 7,571/13,723

The second trial was to determine the pressure angle at the sure angle than is currently used in gearing and produces sig-
following conditions: nificantly reduced bending and surface contact stress for the
0.030 inch top land; 2.1/DP whole depth, 1.15 contact ratio. higher pressure angle gearing. Note that there are other items to
• The calculated outside diameters (Eq. 1) are 2.965 inches pin- be considered, such as ease of manufacturing, and that pressure
ion and 5.141 inches gear angles this high have other considerations to take into account.
• The calculated pressure angle to match these conditions is 35° The purpose of this paper is to determine and quantify the use
• The hob tip radius at these conditions is 0.007 inches pinion / of high pressure angles for gear teeth and to calculate them and
.016 inches gear. not to suggest good design practice.
• Bending stress, PSI, pinion/gear is 61,902/54,990; static torque
rating bending, (in-lb): 16,889/34,460 A typical application for this type of high pressure angle gear-
• Surface contact stress, PSI, pinion and gear: 303,063; static ing would be one with slow speed, large, coarse pitch teeth, and
torque rating surface P/G: 8,866/16,069 lower quality level, although other conditions could also be con-
• This represents a bending stress reduction from the 25 PA sidered for these gears. Applications where a high power density
gearset of 31% pinion and 40% for the gear and high gear tooth strength are required should consider this
• The increase in static torque rating for bending strength is type of gearing.
44% pinion and 67% for the gear Note that these methods can also be used for more typical
• The increase in static torque rating for surface contact pressure angle designs where the user simply wants to design
strength is 17% for both pinion and gear gear teeth and gearsets based on top lands, contact ratio and hob
The third trial was to determine the pressure angle at the tip radius as inputs.
above conditions for the second trial: 0.030 top land, 2.1/DP All gear data and stress calculations were performed using the
whole depth, 1.15 contact ratio — but with the following addi- AGMA GRS 3.1.7 gear rating suite. Due to the length of the pro-
tional requirements: gram data outputs, the data was summarized and shown in more
Hob tip radius equal to 0.020 inches abbreviated format.
• Calculated outside diameters are 2.982 inches pinion and In order to ensure further validation of the gear tooth stresses,
5.159 inches gear it is suggested that alternative FEA (finite element analysis) be
• Calculated contact ratio is 1.22 performed on the gear teeth and the results of this be compared
• Calculated pressure angle to match these conditions is 33.5° to the results from the above analysis.
• Bending stress, PSI, pinion/gear: 65,949 / 58,672; static torque
Dolan and Broghamer (Ref. 6) discuss the applicability of their
rating bending, (in-lb): 15,853 / 32,297
work and stress correction factors to different pressure angles.
• Surface contact stress, PSI, pinion and gear: 305,358; static
torque rating surface P/G: 8,733 / 15,828
• This represents a bending stress reduction from the 25 PA References
1. Townsend, Dennis B. Dudley’s Gear Handbook: The Design, Manufacture,
gearset of 26% pinion and 36% for the gear and Application of Gears, Second Edition, 1992.
• The increase in static torque rating for bending strength is 2. Dudley, Darle W. Handbook of Practical Gear Design, 1984.
35% pinion and 56% for the gear 3. Drago, R. J. Fundamentals of Gear Design, 1984.
• The increase in static torque rating for surface contact 4. Vogel, W. F. Involuometry and Trigonometry, 1945.
5. National Broach. “Modern Methods of Gear Manufacture.”
strength is 15% for both pinion and gear 6. Dolan, T. J. and E.L. Broghamer. “A Photoelastic Study of Stresses in Gear
Tooth Fillets,” University of Illinois Bulletin, 1942.
Summary and Conclusion
A method has been presented to calculate the pressure angle
for gear teeth when the top land, contact ratio, and backlash For Related Articles Search
are specified as inputs. This method does not consider hob tip
radius, which may be a small value or even zero for this calcula- gear design
tion. A zero or very small hob tip radius is probably not a good at www.geartechnology.com
or acceptable design. So another example was shown where a
given hob tip radius was used as an input, and another set of
equations and calculations were shown separately to evaluate the Rick Miller is president and sole member
pressure angle that matches the given hob tip radius in addition of Innovative Drive Solutions LLC, a
mechanical engineering consulting business
to the other input variables as before. This pressure angle would that specializes in gear and geared power
be smaller than either the zero hob tip radius value or the 0.007 drive systems, design and analysis. Based
inch hob tip radius value in the proposed example and is a pre- in Indianapolis, Indiana, Miller helps clients
in the United States and around the world
ferred design, and the resultant gear data was calculated. with his technical expertise. Miller is well-
Gear tooth circular tooth thicknesses were standard in all of known for helping customers solve their technical problems by
these high pressure angle examples but could have been speci- successfully adhering to the tenet, “For every problem, there is
fied as non-standard values if desired and used in the existing a solution.” Miller has created over 300 original gearbox designs
used in a variety of industries. He is the inventor on two patents
calculations. Likewise, the top land values for the pinion and the granted and one pending — a testimony to his creativity and out-
gear were the same (0.030 inch), but could have been different of-the box thinking. Prior to leading his consultancy business
from each other. he was chief engineer of Oerlikon Fairfield in Lafayette, Indiana.
Miller is a member of SAE International and ASME, and is Vice
All mathematical formulas and their derivation were shown.
Chairman of the AGMA Vehicle Gearing Committee.
The results for the examples shown are a much higher pres-

industry news
Toyoda Americas
OPENS GREAT LAKES TECHNICAL CENTER
JTEKT Toyoda Americas celebrated the grand unveiling of their
Great Lakes Technical Center April 19 and 20. Nestled at the
heart of the U.S. automotive industry and just under 40 miles
from the Canadian border, Toyoda’s Wixom, Michigan based
tech center will provide local sales application, turnkey and ser-
vice support to manufacturers in the Great Lakes region.
Attendees caught a first look at the tech center’s four
machines: FH500J horizontal machining center, Stealth 965
vertical machining center and recent additions to the Toyoda “Toyoda customers will benefit from the (Great Lakes) facil-
lineup, Takisawa Taiwan’s NEX-105 and Stealth EX-108 turn- ity, which will serve as our service hub for Michigan as well as
ing centers. All four machines were set with varied application an area for current and future customers to view the machine
demonstrations showing off high speed machining and dynam- capabilities we offer,” said Michigan and Windsor Regional
ic milling applications. Manager, Austin Sievers. “Our doors are open for all area man-
ufacturers, please coordinate visits with your local distributor
representative or myself. We will also be hosting training semi-
nars in the near future for grinding, gear skiving and specific
machining applications.”
There will be no shortage of Toyoda expertise in service and
engineering as the tech center shares the 75,000 sq. ft. facil-
ity with Toyoda’s Remanufactured Products Division (RPD).
Dedicated much to the repairing and remanufacturing of
machines since the 1970’s, RPD will continue to specialize in
returning overworked machining centers to OEM specifica-
tions.
Toyoda would like to offer a special thank-you to their local
distributors KM Industrial Machinery, Network Machinery,
industry partners Seco Tools, Kennametal, Mastercam, Schunk
and master BBQ-er, ‘Q It Up. (www.toyoda.com)
Mazak
ANNOUNCES PRECI FACILITY GRAND OPENING
Mazak customers in Mexico will soon benefit from enhanced The Preci facility encompasses nearly 6,000 square feet,
levels of localized customer service and support with the including training space and a 3,200-square-foot showroom
grand opening of the Preci facility in Queretaro. The brand that will house some of Mazak’s most advanced multi- task-
new building will house applications and service technicians, ing, full 5-axis, horizontal and vertical machining systems. Six
offer training to customers and demonstrate some of the most employees will provide technical and sales support to keep cus-
advanced Mazak machine tool and automation technologies, tomers competitive and productive. (www.mazakusa.com)
including those specifically geared toward the area’s
well-entrenched aerospace and automotive indus-
tries.
“The new building gives Mazak’s customers in
the Queretaro area and surrounding regions even
more access to the technical, engineering and appli-
cations expertise they need to thrive and succeed,”
said Brian Papke, chairman of Mazak Corporation.
“We continue to expand and strengthen our capa-
bilities in Mexico - thanks to Preci - as well as
throughout all of North America while other OEMs
typically trim customer service, support and sales
initiatives to keep overhead costs in check.”

ANCA
CONFIRMS GRAEME BILLINGS AS BOARD
CHAIRMAN
ANCA has announced its board has
confirmed the appointment of an
independent, non-executive chair-
man for the ANCA group board. NEW
Pat Boland, joint co-founder said:
Release
“After a rigorous interview process,
03/2017
with several high-quality applicants,
the board has appointed Graeme
Billings to this role.” KISSsoft Highlights
“Graeme comes from an impres-
sive business background as both a ● Reliability evaluation on system level
senior manager, independent director and chairman for several ● Simplified modeling using predefined
of Australia’s best companies,” he concluded. gear stages
After his appointment, Billings said: “The ANCA Group is ● Calculation of root stresses with FE
a great success story. I look forward to working with the board ● Variation calculation for bearings
● Determination of the unbalance
and management in pursuit of the company’s long term growth
response for shafts
strategy.” KISSsoft USA, LLC ● And many more ...
Formally a senior partner at PricewaterhouseCoopers, as well 3719 N. Spring Grove Road
Johnsburg, Illinois 60051
as leading the firm’s Global Industrial Products sector, Graeme Phone (815) 363 8823 Get your free trial version at
has extensive experience in assurance, transaction and consult- [email protected] www.KISSsoft.com
ing services with multinational and Australian companies in
the automotive, construction and general manufacturing indus-
tries, spanning a 34-year period.
Billings also draws on his experience with acquisitions, merg-
ers and other business investigation areas, including succession
planning. In addition, he was a regular media commentator on
GearTech_KISSsoft_Rel_03_2017_Highlights_89x120_5mm.indd 1 30.03.2017 13:38:32
the industrial products sector.
Billings lives in Melbourne with his wife and they have three
children. He is a passionate sports fan and particularly enjoys
AFL, cricket and golf. PUTTING
This position is effective immediately. (www.anca.com) A LIFETIME
OF
AGMA GEAR
WELCOMES NEW BOARD MEMBERS
DESIGN
The American Gear Manufacturers Association (AGMA)
recently announced the election of Jim Bregi, president of EXPERIENCE
Doppler Gear as the new AGMA chairman of the board, at
TO WORK FOR YOU
the AGMA Annual Meeting held March 30–April 1 in Palm
Springs, California.
Other changes to the board include a new chairman emer- • Reverse engineering • Design reviews
• Gearbox upgrades • Bid evaluations
itus, treasurer, business management executive committee • Custom gearbox design • Tooling design
(BMEC) chairman and technical division executive committee • Specification development • Customized gear training
(TDEC) chairman. • Project management • Equipment evaluation
The new AGMA executive committee is: Jim Bregi, chair- • Vendor qualification • Custom machine design
man, and president of Doppler Gear; John Cross, treasurer, and Charles D. Schultz
president, ASI Technologies, Inc.; Todd Praneis, TDEC chair-
man, and director of product development, Cotta Transmission;
[email protected]
John Grazia, BMEC chairman, and president, GearTec, Inc. [630] 209-1652
and Dean Burrows, chairman emeritus, and president of Gear
Motions, Inc.
Additionally, AGMA welcomes four new members to its
www.beytagear.com

industry news
in the field of digital manufacturing and Industry 4.0,” said

Magnus Ekbäck, vice president and head of business develop-
ment and digital machining for Sandvik Coromant. “With this
cooperation we will significantly strengthen our capabilities
within digital machining.”
“Manufacturing is entering a dynamic new phase as the cyber
and physical worlds converge, and the complex and diverse
industry needs significant innovation to truly progress,” said
PARC CEO Tolga Kurtoglu. “The missing piece for complete
design automation and manufacturing of complex products
has been the integrated coupling of design and manufacturing,
which we have been developing at PARC for many years. We’re
pleased to partner with Sandvik Coromant to see these innova-
tions come to life on the global stage.”
(Left) Jim Bregi, Doppler Gear and

Dean Burrows, Gear Motions, Inc.
board of directors. These directors will serve a three-year term

(2017–2020), effective April 3, 2017. The new board members
were elected by AGMA corporate members in the first quarter
of 2017, and announced during the AGMA Annual Meeting.
The newly elected board members are: Michael Engesser,
president, Reishauer USA; Mike McKernin, president, Circle PARC has been developing technologies for government
Gear and Machine Company; Cory Ooyen, president, Global agencies and commercial clients in the field of digital manu-
Gear and Machining, LLC; and Greg Schulte, president, facturing for almost a decade. Its digital manufacturing suite
Bonfiglioli USA. of technologies helps designers and manufacturers understand
“AGMA is a member driven organization and these indus- real-world manufacturing process constraints during digital
try leaders will join our dynamic board at an exciting time in product design and identifies potential limitations of a supply
its history,” noted Matthew E. Croson, president of AGMA. “I chain early in the design phase, ultimately minimizing time-to-
look forward to working closely with them as we execute on our market and improving overall product quality.
strategic plan and add value into the second century of AGMA’s The strategic research agreement will be governed by a Joint
history.” (www.agma.org) Steering Committee with representatives from both PARC and
Sandvik Coromant. (www.sandvik.coromant.com)
Sandvik Coromant Photo Caption: Saigopal Nelaturi (Area Manager,

Computation for Automation in Systems Engineering) PARC,
Janni Weber (Senior Project Manager) Sandvik Coromant, Mats
SIGNS RESEARCH AGREEMENT WITH PARC
TO DEVELOP DIGITAL MANUFACTURING Bergstrom (Managing Director, Global Business Operations
TECHNOLOGY and Program Manager for Digital Design and Manufacturing)
PARC, Magnus Ekbäck (Vice President and Head of Business
Sandvik Coromant is strengthening its digital manufactur- Development and Digital Machining) Sandvik Coromant,
ing capabilities by signing a strategic research agreement with Tolga Kurtoglu (CEO) PARC, Markus Larsson (Vice President
PARC, a Xerox company, world-renowned innovation cen- of Global Business Operations) PARC, Mats Allard (Project
ter. PARC will provide Sandvik Coromant with a footprint in Manager Virtual Machining) Sandvik Coromant, Michael
Silicon Valley and expert resources for research and develop- Waltrip (Senior Director, Intellectual Property Management
ment in the field of digital manufacturing. and Commercialization) PARC.
PARC will allocate resources to conduct research and devel-
op digital manufacturing technologies for Sandvik Coromant
under the terms of the agreement. Sandvik Coromant will also
acquire all intellectual property (IP) and technology related to
Kapp Niles
FOUNDS METROLOGY DIVISION
PARC’s software for high-level process planning and automated
manufacturing cost estimation for subtractive manufacturing. Kapp Niles has announced the expansion of its product port-
“This partnership is a natural step and in line with Sandvik folio by adding high-end metrology solutions. The new-found
Coromant’s long-term strategy to develop attractive solutions division Kapp Niles Metrology GmbH, based in Aschaffenburg,

Germany, leverages the wealth of experience and technology sentation of “Mixed-reality in Industry 4.0 - Redefining Reality
from R&P Metrology GmbH, whose employees and manage- in Industrial Production” Seco/Warwick presented its latest
ment are joining the new company. Kapp Niles Metrology innovation - Seco/Lens, an application utilizing augmented
designs and builds customized large 4- and 5-axis analyzers reality technology, based on the latest HoloLens holographic
built to VDI/VDE class I. A derivative of the technology is a computer. It is the first such application in Poland and one of
transportable 3-axis device for analyzing gears in the shop on the first in the world used in heavy industry.
cutting machines or even in a gear box. An expansion into the “Digital technology is the basis for the development of the
metrology sector complements the Kapp Niles product port- fourth industrial revolution we are currently witnessing. The
folio for gear and profile grinding up to 8 meters. The new driving force behind these concepts are concrete solutions that
company will also provide sales and support in Europe and utilize the Internet of Things (IoT), cloud computing, augment-
Asia for the smaller gear analyzers and products of Penta Gear ed reality, and advanced analytics. Seco/Warwick is at the fore-
Metrology of Dayton, OH (pentagear.com), which joined Kapp front of the digital revolution in the manufacturing industry,
Technologies in 2015. Both Kapp Niles Metrology GmbH and demonstrating how to effectively leverage digital tools to create
Penta Gear Metrology are innovators in their respective sectors innovative solutions and models. Based on Microsoft technol-
and now join forces for further advancements. Industry 4.0 is ogy, the company has created an integrated ecosystem of data,
just one of the areas customers will benefit from these extensive applications and systems that support its growth and improve
integrated solutions to the gear industry. (www.kapp-niles.com) the efficiency of processes, especially those of an innovative
nature,” emphasizes Dariusz Piotrowski, member of the board
Seco/Warwick at Microsoft in Poland.

“This is a new era of Seco/Warwick equipment application -
the interaction era. Cyber-goggles, so far associated more with
AWARDED PRODUCTION COMPANY OF THE
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the real world. The implementation of virtual technology to our
Seco/Warwick has won a Production Company of the Year title production, maintenance and service of Seco/Warwick systems,
in the Leaders of the Manufacturing World Competition. has become reality and is going to result in substantial benefits
The title given to Seco/Warwick is a recognition of a com- for us and our clients, for example by increasing the mobility,
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the manufacturing sector while achieving significant growth specifies Katarzyna Sawka, Seco/Warwick global marketing
dynamics. director. (www.secowarwick.com)
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© 2017 Smart Manufacturing Technology Ltd.
At the III Innovative Manufacturing Forum, during the pre-

calendar
June 27–29—Power-Gen Europe 2017 Cologne, emerging trends while fostering new industry relationships in
Germany. Power-Gen Europe and co-located Renewable Energy daily networking sessions. Seminars include targeted sessions on
World Europe, is where a rapidly-evolving power industry meets manufacturing strategy, vehicle lightweighting, connected and
to gather information and compare views on shared opportuni- automated vehicles, advanced powertrain, supply chain, sales
ties and challenges. Attracting a worldwide audience, it is a key forecasting, purchasing, talent and designing for technology. For
event for advancing Europe’s energy future. Featuring the lead- more information, visit www.cargroup.org.
ing suppliers, sub-suppliers, service providers and end-users
across the entire power generation value chain, the trade show August 1–3—Ipsen U 2017 Cherry Valley, Illinois.
encapsulates all aspects of today’s centralized and distributed Continuing Ipsen’s long-standing tradition of offering training
power generation sector. Together they combine strategic and that teaches best practices and help improve the performance
technical presentations with the largest trade show exhibition and lifespan of your equipment. Ipsen’s newly remodeled, state-
of power equipment and services in Europe. Conference topics of-the-art space offers an ideal arena for attendees to build and
include renewable energy, energy storage, plant management, refresh their knowledge of heat-treating equipment, processes
digital tools, and strategies for change. For more information, and maintenance through applied learning. For those that prefer
visit www.powergeneurope.com. to stay close to home, Ipsen will also be providing additional
one-day courses throughout the United States. Specific topics
July 5–6—International VDI Congress-Drivetrain that will be covered during these local seminars include vacuum
for Vehicles Bonn, Germany. The electrification of the pow- and atmosphere furnace maintenance best practices, optimiz-
ertrain implies one of the mega trends in transmission devel- ing operations with predictive maintenance and achieving and
opment. This technical advancement has impacted the entire maintaining aerospace compliance. Overall, both training oppor-
automotive industry and affects everyone from the manu- tunities will teach best practices for regaining control of your
facturers, the suppliers and subcontractors up to the drivers equipment and offer expert insight into specific maintenance
themselves. This conference examines the predicted impact issues you might be experiencing on a daily basis. For more
and influence of the new electric and hybrid vehicles on the information, visit www.ipsenusa.com.
market in terms of suitability for mass production. Here the
focus is placed on the requirements that electrified drive sys- August 10—The Changing Landscape of Additive
tems have to fulfill and how they inspire manufacturers and Manufacturing Materials Youngstown, Ohio. SME and
suppliers in engineering and mechatronics to propel innova- America Makes come together to bring you this one-of-a-kind
tive developments to new heights. One of the highlights in seminar. 3D Printing has significantly grown in recent years and
Bonn is the accompanying trade show, which over the years is expected to quickly grow over the next few years. Discover
has grown to become a major marketplace. More than 100 which materials and filaments are most durable, what types of
organizations from around the world present their solutions machines to use, certification/qualification standards as well
covering all aspects of the automotive transmission and its as how to reduce cost, and increase profitability. Participating
components. For more information, visit www.transmission- companies include GE, the U.S. Army, Northrop Grumman, and
congress.com. more. Topics include new materials, aerospace production, mate-
rial implementation, expanding design space and the future of
July 17–21—Coordinate Metrology Society additive manufacturing. For more information, visit smartmanu-
Conference Snowbird, Utah. The Coordinate Metrology facturingseries.com.
Society (CMS) has announced that attendee registration is now
open for the 2017 Coordinate Metrology Society Conference August 21–22—Design and Production
(CMSC). The CMS will convene this year at the Snowbird Engineering 2017 Birmingham, U.K. The Design
Meeting and Convention Center in Snowbird, Utah, July 17–21, & Production 2017 Conference brings together experts,
2017. The eminent membership association for 3-D measure- researchers, scholars and students from all areas of mechani-
ment professionals gathers annually to learn about technol- cal engineering including design engineering, manufacture
ogy achievements, network with industry experts and get a engineering, production engineering, vehicle engineering and
pulse on the metrology industry. Weekly registration includes other related areas such as mechatronics, bio-inspired robotics,
entry to more than 20 technical sessions, workshops, the ever- prosthetic design and bio-inspired design. This conference offers
popular Measurement and Education Zone, CMSC Exhibition an opportunity to attend the presentations delivered by eminent
Hall and networking events, as well as post-conference access scientists, researchers, experts from all over the world. Topics
to all technical papers and presentation materials. CMSC 2017 include reshoring, manufacturing innovations, material science,
affords an educational opportunity for anyone interested in 3D aerospace, maintenance and more. For more information, visit
measurement and inspection solutions utilized in manufactur- www.design-production.conferenceseries.com.
ing, research and development, and various scientific fields. For
the 33rd year in a row, the CMS has connected with metrologists
September 6–8—AGMA 2017 Bevel Gear System
through education and technology. For more information, visit
Design San Diego, CA. Learn how to design and apply bevel
gears systems from the initial concept through manufacturing
www.cmsc.org.
and quality control and on to assembly, installation and main-
July 31–August 3—CAR Management Briefing tenance. Engage in a practical hands-on guide to the bevel gear
Seminars Grand Traverse Resort, Traverse City, Michigan. design, manufacture, quality control, assembly, installation
Initiated by the University of Michigan in 1965, the first Center rating, lubrication and, most especially, application. Engineers,
for Automotive Research Management Briefing Seminars (CAR technicians, and others involved in the selection, application
MBS) hosted only 30 people. When the industry was at its high- and/or design of bevel gear systems should attend. Ray Drago is
est number of employment, the event grew to attract more the instructor. For more information, visit www.agma.org.
than 1,400 attendees annually from more than 35 states and
15 countries−representing industry, academia, media and the
government. CAR MBS leads the industry in providing a con-
text for auto industry stakeholders to discuss critical issues and

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A.G. Davis/AA Gage — Page 31 Liebherr — Pages 5, 12
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You need to talk to Goldstein Gear
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Beyta Gear Service — Page 81 Midwest Gear & Tool — Page 4
Machinery LLC (GGM), of which
www.beytagear.com [email protected] Michael Goldstein was President and
Bourn & Koch — Page 3 Mitsubishi Heavy Industries America — Page 8 primary buyer and seller at his former
www.bourn-koch.com www.mitsubishigearcenter.com company, Cadillac Machinery Co., Inc.
The Broach Masters & Universal Gear — Page 27 Nordex Inc. — Pages 20, 41
www.broachmasters.com www.nordex.com For large departments or whole
Circle Gear — Page 42 Oelheld U.S. Inc. — Page 41 plants, 100% of the SALE proceeds
www.circlegear.com www.oelheld.com
goes to the owner
DTR Corp. — Page 16 Penta Gear Metrology — Page 46
www.dragon.co.kr www.gearinspection.com GGM is the only one experienced
DVS Technology Group — Page 33
www.pittler.de
Reishauer — Page 39
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gear machinery expert to get you the
Excel Gear — Page 24 Riverside Spline and Gear — Page 41
highest value. Gear equipment is not
www.excelgear.com www.splineandgear.com like general purpose machinery; they
Forest City Gear — Page 25 Roberts Sinto Corp. — Page 47 have unique features and capabilities,
www.forestcitygear.com www.sinto.com
which only an expert can describe
Gear Expo — Page 37 Schafer Industries — Pages 15, 17, 19
www.gearexpo.com schafergearheads.com and know to photograph, especially
Gear Research Institute — Page 41 Schnyder S.A. — Page 4 Gleason mechanical bevel equipment,
gearresearch.org www.schnyder.com of which GGM is the leading expert.
Gleason Corporation — Pages 44-45 SMT — Page 83
www.gleason.com masta.smartmt.com GGM has over 55 years of experience
Goldstein Gear Machinery — Pages 40, 86 Star SU LLC — IFC-Page 1, Page 41 buying/selling and auctioning gear
www.goldsteingearmachinery.com www.star-su.com machinery, with a reputation for
Hans-Jürgen Geiger Maschinen-Vertrieb GmbH — Page 40 Systrand Manufacturing — Page 42
www.geiger-germany.com www.systrand.com knowledge, experience and capability
Hardinge Group — Page 21 WZL Gear Conference — Page 12 second to none. GGM, and Michael’s
www.hardingegrindinggroup.com [email protected] prior company, Cadillac Machinery,
Hobsource Inc. — Page 42 were in a joint venture with Industrial
www.hobsource.com
Ipsen International — Inside Back Cover
Plants Corp (IPC) in Industrial Plants
www.ipsenusa.com Ltd (UK) (IPC-UK) and Michael was
Kapp Technologies — Page 13 the primary auction evaluator and
www.kapp-usa.com organizer, for over 10 years. As he
KissSoft USA, LLC — Page 81
www.kisssoft.com
tracks every gear auction, worldwide,
Klingelnberg — Pages 11, Outside Back Cover he has records of what every gear
www.klingelnberg.com machine is sold for.
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addendum
Babbage’s Engines
Though we think of the computer as a distinctly 20th
century invention, Charles Babbage designed several
precursors way back in the early 1800s.
Alex Cannella, Associate Editor
Today, we use electronic mathematical tables for redesigning his original project. The Difference Engine No. 2
everything from astronomy to finance. But when required only 8,000 parts, a fraction of what the original called
Charles Babbage was born all the way back in 1791, these tables for, and could calculate polynomials up to the seventh order.
were all done by hand, and that meant they were susceptible The machine also took Babbage’s earlier idea for a separate
to human error. Babbage spent a portion of his early life dou- printer and added it to the Difference Engine.
ble-checking these tables, and was often frustrated by just how Ultimately, however, the Difference Engine No. 2 met the
many he found. same fate as Babbage’s earlier inventions. Either because of the
That frustration drove Babbage to invent the Difference complexity of the machines or his unyielding personality and
Engine, a behemoth machine designed to calculate polynomial dedication to perfection, Babbage never finished any of his
tables, in 1821. The machine could only use addition, but could machines before moving on to his next idea. To this day, only
still calculate tables utilizing the method of differences. The one full Difference Engine based on the 2.0 model has ever
Difference Engine was run with a simple hand crank, with the been completed, and work on it didn’t even start until 1985,
idea being to literally plug and chug the numbers. It was essen- well after it had been obsoleted by computers.
tially a room-sized calculator, but a thirst for the infallible cal- The Science Museum in London set out to build a Difference
culating power of exacting machinery inspired the government Engine No. 2 by following Babbage’s design both to prove that
to fund the machine’s construction.
Just designing the Difference Engine was no
small feat of genius, but Babbage found that actu-
ally building the machine was an even more diffi-
cult proposition. The design called for a staggering
25,000 parts, including numerous gearwheels, and
each needed to be cut to exacting specifications.
Even after £17,500 of funding from the British gov-
ernment and 12 years of work, all Babbage had
to show for his effort was a prototype for a single
section of the machine. While the prototype drew
plenty of attention, patience and funding eventu-
ally ran out, and the Difference Engine was never
completed.
But Babbage had already moved on to a new
project: The Analytical Engine. Unlike the Just one of the countless gearwheels used to make Babbage's engines function.
Difference Engine, this newest design has been Photo by Marcin Wichary, originally posted to flickr.com (licensed under CC BY 2.0).
hailed as a full-on precursor to the modern com-
puter due to the way it pioneered many design concepts that are it had been a technologically feasible machine and to honor the
still used for computers today. It was structured in two parts, 200th anniversary of Babbage’s birth.
with one being a “store” where much of the setup or interme- But even with modern manufacturing techniques, recreating
diate solutions could be temporarily kept and results could be Babbage’s Difference Engine No. 2 was a 17-year effort fraught
printed, the other a “mill” where the actual number crunching with technical and financial challenges. While the calculat-
happened. The design mirrors how computers work today, with ing half of the machine was completed in 1991 just in time for
memory storage and a processor separate from each other. the anniversary, the rest wouldn’t be completed until 2002. But
The Analytical Engine also utilized a punch card system to eventually, the team managed to put it together without deviat-
program its calculations. Babbage borrowed the idea for the ing from Babbage’s design, and the Difference Engine is still on
punch card system from the Jacquard loom. The idea would, in display at the Science Museum in London today.
turn, later become a necessary part of early modern computer Several other artifacts of Babbage’s work are on display else-
systems. It was also capable of a much wider range of calcula- where in the world. The Smithsonian displays a single segment of
tions than the Difference Engine, now able to subtract, multiply the full machine that was made in 1853, and there’s a replica that
and divide. was created for a Microsoft executive, but the only original, full
Much like with the Difference Engine, Babbage moved on to Difference Engine to ever be completed resides in London.
new ideas before the Analytical Engine was ever built, this time

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TEAMPLAYER.
GEAR MANUFACTURING SOLUTIONS
FOR MAXIMUM PERFORMANCE
BY KLINGELNBERG
KLINGELNBERG OERLIKON HÖFLER

MEASURING TECHNOLOGY BEVEL GEAR TECHNOLOGY CYLINDRICAL GEAR TECHNOLOGY
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BEVEL GEAR TECHNOLOGY MEASURING TECHNOLOGY CYLINDRICAL GEAR TECHNOLOGY DRIVE TECHNOLOGY

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What is the new Samputensili SG 160 SKY GRIND machine?

What is the new Samputensili SG 160 SKY GRIND machine?

What are some of the benefits of the new SG 160 SKY GRIND machine?

What are some of the benefits of the new SG 160 SKY GRIND machine?

JUN

www.geartechnology.com THE JOURNAL OF GEAR MANUFACTURING

This ensures a smaller machine footprint and

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New 10-4 Gear Shaper

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Simultaneous chamfering with ChamferCut –

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Visit MachineToolBuilders.com/Burri for details.

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Downtime is a black hole that impairs productivity, kills

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Chamfering in the work area

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UPCOMING TRADE FAIRS:

Measuring directly on the shop floor saves time and money.

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For Related Articles Search

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Product Spotlight: Liebherr’s IG

June 2017 | GEAR TECHNOLOGY 27

Wind Turbine Gearbox Reliability

A high number of wind turbine gearboxes do not

Figure 3 RomaxWind analysis model of GB3, including NREL 2.5 MW

Figure 6 Planetary bearing L10 life predictions show improved life

Figure 4 Flank twist. Figure 5 Crowning and changing center distance.

Figure 6 Crowning and profile angle.

Figure 8 Modification of the grinding worm.

Figure 10 Dressing the grinding worm.

Figure 11 Exemplary definition of twist.

Figure 14 Mating gear ground with natural twist.

Figure 2 Tooth mesh surface structure and excitation change.