GEAR SOLUTIONS MAGAZINE

Your Resource for Machines, Services, and Tooling for the Gear Industry

ISSUE FOCUS
GEAR TOOTH STRENGTH ANALYSIS OF HIGH PRESSURE ANGLE CYLINDRICAL GEARS

Gear Shaping | Gear Hobbing

 GEAR TOOTH STRENGTH ANALYSIS OF

HIGH PRESSURE
ANGLE CYLINDRICAL GEARS
COMPANY
PROFILE

WOLVERINE BROACH CO. INC.

JUNE 2018

JUNE 2018
gearsolutions.com
 Achieving Increased Profits and Response Times
with Modular Vacuum, Atmosphere Furnaces

“Initially, what appealed to us about this Ipsen

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

Customer Story

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

go.IpsenUSA.com/Customer-Stories

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

www.toolink-eng.com

303-776-6212
 Power Skiving Days
Rochester, NY, June 20-21
Experience first-hand the enormous productivity
and quality benefits of Gleason Power Skiving at
our Power Skiving Days. It’s a unique opportunity to
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Register at: www.gleason.com/psdays

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2     gearsolutions.com
© Gleason Corporation. All rights reserved.
FEATURES

30
GEAR TOOTH STRENGTH ANALYSIS OF
HIGH PRESSURE ANGLE CYLINDRICAL GEARS
High pressure angle gears are not expected to show better mechanical behavior in
high power transmissions than gears with conventional designs.

40 EVALUATING THE UNKNOWN GEOMETRY

OF HIGH ACCURACY GEARING
Finding the addendum modification coefficient using the base tangent length (BTL)
method is found to be useful for gear parameter evaluation of an unknown gear.

DRIVING GEAR DEVELOPMENT

Gleason technologies help SEW Eurodrive meet global demand for compact,
quiet, and very high-efficiency spiral bevel gear units.
46

50 SERVICING THE ENTIRE PROCESS

COMPANY PROFILE  Wolverine Broach Co. Inc. has developed a reputation
for craftsmanship, design, engineering, and support services.

June 2018     3
 Manufacturers of:

and Universal Gear Company

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

4     gearsolutions.com
 JUNE 2018  •  VOLUME 16, NUMBER 6
DEPARTMENTS
INDUSTRY
8 NEWS
Reports, data, and developments to keep
you aware of what’s happening with your
colleagues in the gear-manufacturing
industry around the country and world.
Röhm to feature diverse line-up Mazak to spotlight HYBRID multi-tasking
of workholding solutions at IMTS in booth at IMTS 2018

17
In this section, the premier supporter of gear manufacturing in the United American
States and beyond shares news of the organization’s activities, upcoming
educational and training opportunities, technical meetings and seminars, Gear Manufacturers
standards development, and the actions of AGMA councils and committees. Association

MATERIALS TOOTH HOT

22 MATTER 24 TIPS 26 SEAT
E. BUDDY DAMM BRIAN DENGEL D. SCOTT MACKENZIE

INCREASING GEAR SET WORMS AND WORM WHEELS – ENDOTHERMIC ATMOSPHERES

POWER DENSITY A PRIMER USED FOR HEAT TREATING
High-strength, high-toughness steels can Worm gear pairs are an excellent design Why keeping CO content of a furnace
be used to increase power density while choice when you need to reduce speeds must be stable at a value of 20 percent is
addressing critical components of gear and change the directions of your motion, critical for accurate carbon control of the
set design. and they have many other applications endothermic atmosphere.
as well.

PRODUCT Q&A
54 SHOWCASE 60
New products, trends, services and
developments in the gear industry.

RESOURCES
58 MARKETPLACE

CURTIS DICK
59 ADVERTISER INDEX
Director of Quality with
COVER PHOTO: SHUTTERSTOCK Riverside Spline and Gear Inc.

Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway, Pelham, AL 35124. Phone (205) 380-1573 Fax
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No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any
information storage-and-retrieval system without permission in writing from the publisher. The views expressed by those not on the staff on Gear Solutions
magazine, or who are not specifically employed by Media Solutions, Inc., are purely their own. All “Industry News” material has either been submitted by the
subject company or pulled directly from their corporate website, which is assumed to be cleared for release. Comments and submissions are welcome, and can
be submitted to [email protected].

June 2018     5
 FROM THE
EDITOR David C. Cooper
PUBLISHER

Chad Morrison
ASSOCIATE PUBLISHER

Focusing on important industry EDITORIAL

staples: gear shaping and hobbing Kenneth Carter
EDITOR

I don’t want to steal too much of AGMA’s thunder, but I do want to mention that its annual
meeting in Naples, Florida, was a great success for the organization. Many of AGMA’s
members were recognized for what they have done for the industry. It’s making some
Russ Willcutt
CONTRIBUTING EDITOR

interesting changes to how it wants to continue to help the gear manufacturing industry, Jennifer Jacobson
including the formation of a new committee on the latest emerging technology. ASSOCIATE EDITOR
Make sure you check out the AGMA section in this issue to get the scoop on all the
details of what happened at the annual meeting.
SALES
Consider the AGMA information just an appetizer to what you’ll find in the June issue
of Gear Solutions. Chad Morrison
ASSOCIATE PUBLISHER
With a focus on gear shaping and gear hobbing, we’re offering up several technical
papers that address these important industry staples. Dave Gomez
A paper from Dr. Alfonso Fuentes-Aznar and Dr. Ignacio Gonzalez-Perez talks about gear REGIONAL SALES MANAGER
tooth strength analysis of high pressure angle cylindrical gears. Prasmit Kumar Nayak, A.
Velayudham, and C. Chandrasekaran share their approach in evaluating the unknown
CIRCULATION
geometry of the high accuracy gears of a CNC machine tool.
Scott MacKenzie, our resident Hot Seat expert, goes into detail on how endothermic Teresa Cooper
atmospheres are used for heat treating. MANAGER

And Tooth Tips columnist Brian Dengel has written another relatable column. This Jamie Willett
time it’s a primer on worms and worm wheels. ASSISTANT
In our company profile, I talk with Wolverine Broach’s president and vice president of Cole Morrison
sales. They have made some impressive strides with broaching and have a recent award ASSISTANT
to show it.
And last, but not least, I had the pleasure of chatting with Riverside Spline and Gear’s
director of quality, Curtis Dick. Riverside has recently added several pieces of machinery DESIGN
that will help the company meet its customers’ urgent needs. Rick Frennea
You’ll find that and much more in this issue. I hope you learn something new. CREATIVE DIRECTOR
Enjoy, and, as always, thanks for reading!
Michele Hall
GRAPHIC DESIGNER

CONTRIBUTING
WRITERS
ALFONSO FUENTES-AZNAR
IGNACIO GONZALEZ-PEREZ
KENNETH CARTER, editor PRASMIT KUMAR NAYAK
A. VELAYUDHAM
Gear Solutions magazine C. CHANDRASEKARAN
[email protected] UWE GAISER
(800) 366-2185 x204 D. SCOTT MACKENZIE
BRIAN DENGEL
MARY ELLEN DORAN
E. BUDDY DAMM
Vertical Logo

Coop w
PUBLISHED BY MEDIA SOLUTIONS, INC.
P. O. Box 1987 • Pelham, AL 35124
(800) 366-2185 • (205) 380-1580 fax
David C. Cooper Chad Morrison
PRESIDENT VICE PRESIDENT

Teresa Cooper
6     gearsolutions.com OPERATIONS
 FELLOWS 10-4 GEAR SHAPERS REMANUFACTURED IN 2017

Y ea h , w e ’v e got t hat!

We have the world’s largest stock

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

REMANUFACTURED
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860-223-7778
www.NewEnglandGear.com

June  2018     7
343 JOHN DOWNEY DRIVE • NEW BRITAIN, CT 06051-2907 • PHONE 860-223-7778 • FAX 860-223-7776 • [email protected]
 INDUSTRY
NEWS NEW TRENDS, SERVICES & DEVELOPMENTS

Mazak to spotlight
HYBRID multi-tasking
in booth at IMTS 2018
At the 2018 International Manufacturing
Technology Show (IMTS), Mazak will feature
its advanced HYBRID Multi-Tasking tech-
nologies in booth #432000 in the West Hall,
and 30 of its newest machine tool and auto-
mation systems in the South Hall at booth
#338300. New to the South Hall booth this
year is the Mazak Digital Plaza, a special area
for visitors to experience innovations such
as SMOOTH Link, the Mazak SmartBox, and
other powerful SMOOTH Technology digital
solutions.
As manufacturing technology contin-
ues its rapid growth, especially in terms
of machine tools and digital connectivity/
solutions, Mazak has continued to develop
solutions that meet the needs of the robust
and expanding North American manufac-
turing sector. At IMTS 2018, Mazak’s two
booths will offer visitors a glimpse of the
future direction in which manufacturing
The KZF-S collet chuck is especially well suited for clamping gears/workpieces that have an external plane or
gear teeth geometries accessible from the outside. (Courtesy: Röhm) is heading.
“IMTS 2018 comes during our company’s
100th anniversary,” said Dan Janka, presi-
Röhm to feature diverse ing gears/workpieces that have an external dent of Mazak Corporation, “and we look for-

line-up of workholding
plane or gear teeth geometries accessible ward to demonstrating how much manufac-
from the outside. Additionally, the chuck turing has changed over a century of innova-
solutions at IMTS allows face and ID diameters to be turned
or ground concentric to outer gear pitch
tion, as well as where the company will take
manufacturing in the next 100 years. Our
At IMTS 2018, set for September 10-15, Röhm diameters. new second booth has the perfect position
Products of America will present a wide Röhm will also showcase its EASYLOCK to show Mazak’s commitment to additive
range of workholding solutions that lead to clamping system, a zero-point palletization manufacturing and HYBRID Multi-Tasking
higher levels of efficiency in turning, mill- solution that reduces setup times by up to 90 technology, while our main booth has some
ing, grinding, and drilling applications as percent. With a standardized interface and of the most technologically advanced inno-
well as enable lights-out manufacturing. level of precision and repeat accuracy of less vations our company has ever developed.”
The workholding specialist will also dem- than 0.005 mm, EASYLOCK can be outfitted Mazak’s HYBRID Multi-Tasking series
onstrate how the company is a single source with a large range of Röhm’s collet chucks, serves as another step toward the realiza-
supplier for chucks, centers, face drivers, lathe chucks, and vises for full flexibility via tion of true DONE IN ONE® manufacturing.
rotating workholding, fixtures, palletizing, its modular design. The clamping system is In the new West Hall booth, Mazak will fea-
and robot gripping solutions. equally well suited for vertical, horizontal, ture new technologies like wire arc additive
A must-see for visitors to booth #432528 or multi-axis machining. manufacturing and multi-laser metal depo-
will be a powered external clamping chuck sition. While “multi-tasking” has become
for gear surface face grinding. The KZF-S col- MORE INFO www.rohmdonein60.com increasingly commonplace, these revolu-
let chuck is especially well suited for clamp- www.rohm-products.com tionary HYBRID systems promise to trans-

SEND US YOUR NEWS Companies wishing to submit materials for inclusion in Industry News should contact the editor,
Kenneth Carter, at [email protected]. Releases accompanied by color images will be given first consideration.

8     gearsolutions.com
 THEEMAGVL MACHINES
MAX. PERFORMANCE
GUARANTEED

HIGH FULL
COMPACT
STRENGTH AUTOMATION

VERTICAL
MACHINING:
SAFE AND
EFFICIENT

Workpiece Workpiece
diameter, max. diameter, max.
4 in. 8 in.
At IMTS, Mazak will have a special area for visitors to experience innovations such as SMOOTH link, the Mazak Length, max. Length, max.
6 in. 8 in.
SmartBox, and other powerful SMOOTH Technology digital solutions. (Courtesy: Mazak USA)

form manufacturing just as Multi-Tasking

once did.
Riccardo Rubino joins
At its South Hall booth, the Digital Plaza Star SU as Americas
will spotlight new SMOOTH Technology
enhancements such as SMOOTH Link, a operations manager Workpiece
diameter, max.
Workpiece
diameter, max.
digital connectivity solution that makes 12 in. 16 in.
remote monitoring as simple as installing a Star SU of Hoffman Estates, Illinois, Length, max.
10 in.
Length, max.
12 in.
commercial-off-the-shelf wireless network. announced the appointment of Riccardo
The company will also demonstrate the user- Rubino as its new operations manager for HIGHLIGHTS
friendly programming capabilities and pro- the Americas. + Smallfootprint=Reducedfloorspacecost
cessing speed of its MAZATROL SmoothX and “Riccardo brings operations and supply + Simple workpiece conveyor & interlinking = Flexibility
andlowerautomationcosts
MAZATROL SmoothG CNC controls. chain leadership experience from positions + Integratedautomationfornoadditionalcost
In addition to the digital technology on held both in the U.S. and Italy,” said David + Shorttraversedistances=Minimalidletime,
display, the South Hall booth will feature Goodfellow, president of Star SU LLC. “He increasedperformance

numerous machine tool innovations and will work closely with me overseeing opera- + Standardizedpartsstrategy=Lowmaintenancecosts
new automation solutions. tions starting with for the Star SU Hoffman + Machiningofchuckedparts=Standardizedmachine
platform
Mazak will also highlight automation Estates and Star SU Federal de Mexico and
+ Operatorfriendly=Quickset-upandchange-over
solutions for job shops with new systems taking over the quality control for those + Highenergyefficiency=Reducedenergycost
such as the Multi-Pallet Pool (MPP), a operations. I am confident in Riccardo’s
space-saving palletized system for manu- experience in his previous leadership role
facturers who cannot accommodate a full will help lead our team in continuous
PALLETECH or MAZATEC SMS system. The growth and enhance operational activities.”.
company will also demonstrate some of its Rubino has spent the last six years build-
new machine tool features, including new ing a career surrounding operations, pro-
gear skiving software solutions built into curement, sales, and product management
the latest INTEGREX platforms and friction with Somaschini North America (South
stir welding, a HYBRID Multi-Tasking join- Bend, Indiana) and Somaschini Automotive
EMAG L.L.C.
ing technology. (Bergamo, Italy). He earned a BS and MS in 38800 Grand River Avenue
Industrial and Management Engineering Farmington Hills, MI 48335 · USA

MORE INFO www.mazakusa.com

Phone: +1 248 477-7440 · Fax: +1 248 477-7784
while studying in Italy. E-Mail: [email protected]
www.emag.com
June 2018     9
INDUSTRY
NEWS

Star SU is the go-to-market coopera- covers testing and calibration performed

tive partnership of Star Cutter Company using standard, non-standard and labora-
of Farmington Hills, Michigan, and SU tory-developed methods. The company also
America, Inc., the U.S. sales and manufactur- provides regional customer support and
ing unit to SAMP, S.p.A. training services.
Star SU, LLC offers a wide variety of AIMS was founded in 2009 to equip the
machine tools, precision cutting tools, and industry with the tools to perform accurate,
services including: flexible three-dimensional inspection for
vertical gear hobbing machines in-process and post process parts. In 2015,
chamfering and deburring machines the Dayton, Ohio-based OEM launched
gear grinding machines its line of Revolution LM and HB series
gear shaving machines coordinate measuring machines designed
tool and cutter grinding machines and engineered to introduce and bring
gear hobs and milling cutters Renishaw 5-axis measurement technology
gear shaper cutters and shaving tools to the shop floor and the laboratory. AIMS’
scudding® and power skiving tools Revolution line of CMMs are exclusively
chamfer and deburring tools supported by Renishaw technology through
gundrills probe heads, touch probes, scanning probes,
form tools and reamers incremental encoder scale systems, change
pcd tooling racks, styli, controls, and Modus software.
cryogenic cutting tools Faster measuring speeds, enhanced accu-
Riccardo Rubino spent the last six years building a
carbide blanks and preforms career surrounding operations, procurement, sales,
racy, higher throughput, and lower cost of
tool coatings and product management. ownership make the Revolution series prod-
tool life cycle management services ucts especially suited for the quality con-
The precision measuring head and probe trol process demands of efficiency-driven
MORE INFO www.star-su.com system triple productivity, collecting data manufacturers and the growing number of
at a rate of 4,000 points per second. Infinite smart factories and automated operations.
positioning and 5-axis motion allows users In addition to matching customer require-
AIMS brings 5-Axis CMM to access complex features while flexible tip ments with the right turnkey CMM system,

technology to Mexico
sensing enhances accuracy. The SFP2 surface AIMS provides installation, service, support,
finish probe increases the REVO system’s sur- and training. Machine retrofits and refur-
and Central America face finish measurement ability.
For 5-axis touch trigger applications, the
bished equipment are also available.

AIMS Metrology named Jose Luis Duarte LM is also available with Renishaw’s PH20 MORE INFO www.aimsmetrology.com
business development manager for Mexico which increases throughput three times fast-
and Central America. The coordinate mea- er than traditional indexing heads, offers
suring machine OEM is expanding its reach faster calibration and infinite positioning.
in Mexico and the southernmost region of Linear motors provide submicron accuracy
North America to help automotive and aero- while eliminating the maintenance and
space manufacturers eliminate production downtime associated with belt and pulley
bottlenecks, boost part quality, and mini- designs. Modus software supports offline
mize maintenance costs. AIMS builds and programming, true 5-axis measurement
assembles its Revolution Series CMMs in the programs, full simulation, crash detection,
United States and equips the machines with and the capability to leverage large amounts
Renishaw 5-axis scanning and touch trigger of product information.
probes for higher throughput and accuracy. The Revolution HB is also built with
“Customers are asking for better part Renishaw’s 5-axis PH20 and is the only
quality and shorter delivery schedules,” said mobile 5-axis CMM on the market. A unique
Duarte. “But manufacturers acknowledge undercarriage equipped with one steer and
that conventional CMMs are often a choke two stationary wheels allows two operators
point. Maintenance is expensive and service to easily move the unit anywhere on the
support lacking. AIMS CMMs are engineered shop floor. A 110/220 volt outlet eliminates
to boost throughput and improve inspection the need for shop air. A polymer-cast base
ratings. Service and support are also critical includes built-in vibration resistance and
components for AIMS.” thermal stability. Mechanical bearings add
AIMS’ laboratory-grade Revolution LM additional protection from the harsh shop
can be fitted for touch or non-contact inspec- floor environment. Jose Luis Duarte will lead AIMS Metrology’s expansion
tion. Unlike other systems on the market, AIMS is ISO/IEC 17025:2005 accredited in Mexico and the southernmost region of North
the LM features Renishaw’s REVO 2, the for calibration from the ANSI-ASQ National America in support of automotive and aerospace
industry’s most advanced scanning probe. Accreditation Board. ISO/IEC 17025:2005 manufacturers.

10     gearsolutions.com
Southern Midwest “Staying true to our founder’s vision, we
have built an excellent reputation in the
Methods’ product line strategy offers
only the most advanced, optimal technol-
region strengthened machine tool industry by closely partner-
ing with machine builders and customers, as
ogy for each machining discipline or class.
Machine tool partners include Nakamura-
for Toyoda customers well as providing strong application exper- Tome, Yasda, FANUC, KIWA-Japan and, most
tise,” said Scott McIver, Methods chairman recently, Niigata Machine. EDM partners
TEKT Toyoda Americas Corporation wel- and third-generation owner. “We offer a include FANUC Wire EDM’s and new part-
comed ACI Machine Tool Sales, LLC as the total service solution from design and appli- ner Ocean Technologies Co., Ltd. In addi-
latest edition to its distribution network. cations to engineering, installation, training, tion, Methods 3D, Inc. provides the indus-
ACI Machine Tool Sales was founded in 2001 and unmatched support, to help manufac- try’s most advanced 3D printing solutions
by owner Mark Cox, originally selling and turers be more profitable, productive, and through 3D Systems and MarkForged. For
servicing machine tools in its home state of competitive.” measurement and inspection solutions,
Kentucky. ACI’s continuous success has led to
a growing team of more than 15 members
and expansion into four surrounding states.
The partnership with ACI will facilitate
service and sales efforts for Toyoda manu-
facturing customers in Kentucky, southern
Ohio, and southern Indiana. Along with an High Tech is our Business
extensive network of knowledgeable sales
personnel, ACI offers customers extended
aid out of its Lawrenceburg, Kentucky, tech- ALD is a leader in vacuum
nical facility through turnkey engineering process technology and Heat
solutions and more than 10 machine tool treatment services.
models on show.
LEADERS IN THE
MORE INFO www.toyoda.com CONTROL OF DISTORTION
www.acimachine.com/toyoda ALD Thermal Treatment, Inc.
+ Low Pressure Carburizing
+ High pressure gas quenching
+ Gas Nitriding
Methods Machine Tools + Ferritic Nitro-Carburizing
celebrates 60 years + Plasma Carburizing
+ Normalizing
serving manufacturers + Hardening
+ Annealing
This year, Methods Machine Tools, Inc., + Brazing
North America’s foremost supplier of lead- + Cryogenic Treatments
ing-edge precision machine tools, automa- + Engineering services and
tion, and additive manufacturing solutions, process development
is celebrating its 60th anniversary. Founded + Prototype and trials
in November of 1958 with three employees
and a few refurbished machines, Methods
has grown into one of the largest, most inno-
vative, high-precision machine tool suppliers Global Service Centers
in North America. Methods today has rough- Enrique Lopez – Sales and Marketing
ly 350 employees, eight sales and technology  Limbach-Oberfrohna Email: [email protected]
centers, and more than 35,000 machines Germany Phone +1 (810) 357-0685
installed throughout North America, These  Port Huron, Michigan
range from EDM machines to sophisticated ALD Thermal Treatment, Inc.
USA 2656 24th Street
5-Axis CNC machining centers to state-of-
 Ramos Arizpe, Coahuila Port Huron, MI 48060, USA
the-art robotics, automation, and 3D print-
ing solutions. Mexico
The company’s founder, Clement McIver
Sr., established principles that have contin- www.aldtt.net
ued to set Methods apart from conventional
importers or distributors: “Anyone can sell
a machine. But not everyone provides the
ALD is a subsidiary of AMG Advanced Metallurgical Group N.V.
extra effort that makes a difference on a
company’s bottom line.”
June 2018     11
INDUSTRY
NEWS

To commemorate its
anniversary, Methods
will be hosting open
houses, holding
technology events, and
introducing new product
lines throughout
the year. (Courtesy:
Methods Machine Tools
Inc.)

Methods offers Digital Optical Comparators plement an extensive, national network of dis- rates a new coating and geometry specifically
from VISIONx INC. tributors and dealers, offering the latest tech- for holemaking in steel and cast iron, as well
Demonstrating an unparalleled com- nology and automation solutions, machines, as Niagara Cutter products such as advanced
mitment to quality and reliability, many of training, spare parts, and engineering sup- high feed milling tools with grades and geom-
Methods’ machine manufacturer partner- port demanded by manufacturers. In addi- etries designed for the highest possible effi-
ships have been long term, such as being tion, the company has state-of-the-art auto- ciency even in the toughest materials.
the exclusive U.S. importer of premier mation centers in three locations as well as As a one-stop shop for optimizing manu-
Nakamura-Tome multitasking turning cen- 3D printing labs throughout the U.S. facturing processes, Seco will unveil its new
ters for 35 years, and 25 years with FANUC consultancy service, which will complement
as importer of the world’s most popular tap- MORE INFO  www.methodsmachine.com the company’s existing well-known services
ping/ drilling FANUC RoboDrill machining like STEP training and SecoPoint inventory
centers and FANUC Wire EDM machines for management. The consultancy will use an
all of North America. The close, collabora- Seco showcases tooling extensive evaluation process that examines

innovations and turnkey

tive relationships with Nakamura-Tome and every aspect of a company’s operations to
FANUC have provided Methods’ customers identify all of the factors affecting its bottom
leading machine technology solutions for
decades. In addition, Methods’ close atten-
services at IMTS 2018 line. Visitors will be among the first to learn
more about this new service and how it will
tion to applications and dedicated service For the 2018 International Manufacturing give manufacturers the opportunity for truly
ensures productive, profitable, customer Technology Show (IMTS), Seco will spotlight comprehensive process optimization.
centric solutions and support. the company’s innovative new tools and
“We are excited to celebrate our 60th growing range of services at booth #431564 DOUBLE QUATTROMILL 22
anniversary milestone,” said Jerry Rex, presi- in the West Hall. Additionally, Seco will offer Seco’s new Double QuattroMill 22 face
dent and CEO of Methods. “Our dedicated, visitors the opportunity to interact with its mill for roughing and semi-finishing deliv-
experienced team, together with our power- products and technology via an immersive ers the next level of performance with its
ful partnerships, has provided us a strong augmented reality (AR) experience. free cutting geometry. Its innovative insert
foundation for serving our customers. We Among Seco’s exciting new tooling solu- placement reduces cutting forces, leading
are proud of our heritage and are looking tions at the show is the Double QuattroMill™ to workpiece stability, improved tool life
forward to further expand our leading tech- 22, a double-sided version of the company’s and maximum productivity. The Double
nology solutions in machine tools and auto- aggressive line of face milling tools, and the QuattroMill 22 is ideally suited for applica-
mation, including the most proficient ways company’s newly redesigned Perfomax™ tions in a wider range of part materials than
to apply and support them.” indexable insert drills. Seco’s solid tooling ever before, including steel and cast iron as
Strategically located across the U.S., display at the show will also include the well as 15-5 stainless steel and super alloy
Methods Sales and Technology centers com- Feedmax-P drill configuration that incorpo- materials such as titanium and Inconel®.
12     gearsolutions.com
FEEDMAX-P ation, the drill’s flutes have improved helix
The new Seco Feedmax-P drill gives manu- angles along with smoother chip flute exits
facturers the potential to significantly boost and Seco’s engineered wave pattern, which
holemaking performance beyond that of minimizes contact between chips and flute
current drilling technology for ISO P (steel) surfaces.
and cast-iron workpiece materials. The solid Furthermore, for up to 140 percent lon-
carbide Feedmax-P drills can increase drill- ger drill body tool life, Seco laser hardens
ing productivity by up to 35 percent while the fronts of Perfomax’s flutes. A hardness
also providing longer tool life due to the of HRC 60 allows the drill to withstand chip
combination of the drill’s new geometry erosion for much longer periods of time.
and advanced TiAlN coating. Together with Perfomax drill bodies are available in
the drill’s strong point geometry, cutting diameters ranging 0.594” to 2.375” (15 mm
speeds of 623 feet/min are possible in 4140 to 59 mm); and in most spindle interfaces.
alloy steel without sacrificing tool life.
Seco offers the Feedmax-P in diam- MZN AND MBZ HIGH FEED
eters ranging from 0.078” to 0.787” (2 mm MILLING CUTTERS
to 20 mm). All drills come standard with Niagara Cutter high feed MZN410R and
through-the-tool coolant channels to ensure MZN510R AlTiN-coated solid carbide end
maximum performance. mills bring high wear resistance and supe-
Custom versions such as intermediate rior performance to applications that involve
sizes and chamfer and step drills are avail- machining mold and die components from
able upon request. hardened steel, cast iron or nickel based
The newly redesigned Seco Perfomax indexable
insert drill offers exceptional productivity and longer super alloy workpiece materials.
PERFOMAX tool life. (Courtesy: Seco) Niagara Cutter’s line of high feed milling
A drill body that will stand the test of tools also includes the MBZ tools, ball end
time, the newly redesigned Seco Perfomax mills designed for the rough and finish mill-
indexable insert drill offers exceptional pro- Featuring higher drilling parameters as ing of contours and complex shapes for mold
ductivity and longer tool life. well as exceptional chip control and evacu- and die steels.

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▪ Interface to GEMSTM with data exchange
▪ Shaft editor with background drawing
▪ Calculation of conical compression springs
▪ And many more ...

Gleason Sales Get your free trial version at

[email protected] www.KISSsoft.com

June 2018     13
INDUSTRY
NEWS

Overall, when used in high feed mill-

ing operations, these cutters reduce
Whittemore Company Headquarters in Elgin, Illinois. The company
has a history in America dating back to its
machining time and costs by allowing adds cutting tool founding in 1952 as Precision Twist Drill in
use of one tool for a wide range of opera- suburban Chicago. While the Precision Twist
tions, maximizing material removal rates manufacturer to portfolio Drill brand has developed a focus on HSS
and allowing close-to-profile pocketing of drills, the company has added other brands
90-degree walls. The Whittemore Co. has added the cutting to complete its manufacturing portfolio
The technique also minimizes semi- tool brands of Precision Twist Drill, Dormer, including Union Butterfield for HSS taps,
finishing operations to further increase Pramet and Union Butterfield to its already Dormer for high-performance drills, and
machining efficiency. broad portfolio of products it represents. Pramet for a complete indexable line.
These brands are manufactured by Today, Dormer Pramet is a one-stop man-
MORE INFO www.secotools.com Dormer Pramet, which has North American ufacturer for round and indexable cutting
tools for milling, drilling, hole-making, and
turning.
Russ Reinhart, national sales manager
for Dormer Pramet, said, “We are very

FORGING
pleased to welcome The Whittemore Co.
to our team. We have a passion for cutting
tools and see great value in partnering with
others who have a similar passion. Our team
members work hard to grow business and
ensure the needs of our distributors and

AHEAD
end users are met.”
Dave Zaval, president of Whittemore,
said, “Dormer Pramet and its long-standing
heritage of exceptional cutting tool brands
align with our company’s strategic direction.
Together, I am confident that we will pro-
vide robust solutions to our customers’ met-
alworking needs. We are excited to enter our
next phase of growth with Dormer Pramet

OF THE PACK
on our team.”

MORE INFO Whittemore-inc.com

Big Kaiser Precision

Tooling names marketing
communications manager
Big Kaiser Precision Tooling has named
Gillian Campbell as its marketing commu-
nications manager. She will oversee the com-
pany’s marketing efforts.
“Gillian is an experienced marketing pro-
Fast. fessional with a background in manufactur-
No Fine Print. ing and metrology. I’m confident Gillian will
be a good fit for Big Kaiser and round out the
No Premium. talented group we already have in place to
help us drive marketing and sales activity,”
At McInnes Rolled Rings, we provide quality said Jack Burley, vice president of sales and
products, shipped fast. And we partner that with engineering.
exceptional customer service to forge the perfect Campbell brings more than 20 years of
partnership with our customers. experience in content strategy to the role.
She has worked on the marketing teams for
several manufacturers – most recently at a
precision metrology company. She also previ-
1.877.695.0301  www.McInnesRolledRings.com ously served as editor of Quality magazine
at a time when the publishing industry was
14     gearsolutions.com
 Liftomatic powered 60 YEARS
transporter makes ON THE
drum handling easy CUTTING EDGE
Liftomatic Material Handling, Inc., an
industry-leading material handling equip-
ment manufacturer, recently introduced
the Ergo-PWPL-750 powered drum handling
transport.
Then
The Ergo-PWPL-750™ is a completely and…
NOW
self-contained, powered drum handling
transport that engages, lifts, lowers, and
Gillian Campbell moves all steel, plastic, and fiber drums.
The unit incorporates power drive forward
going through a digital transformation. and reverse, as well as power lift and lower
“I’m excited about to the opportunity to features for moving drums quickly and
lead the marketing team at Big Kaiser and safely in plants, warehouses, and laborato-
continue to increase the company’s visibility ries. Varying weight capacities are available
in the industry,” Campbell said. between 650 and 1,000 pounds. As part of
Liftomatic’s Ergo-Matic® line, the unit is
MORE INFO www.us.bigkaiser.com equipped with a fully programmable set of 60 Year s o n t h e
controls for easy operator adjustment.
Additional features include regenerative Cutti
Southern Gear &ng Ed
Machine ge
is celebrating
JTEKT Toyoda Americas braking, available in straddle leg or fully 60 years of leading the way in custom
signs Phillips Corporation
counterbalanced versions, as well as EE
and spark resistant ratings. All Ergo-Matic® Southern Gear
precision gear manufacturing. Our
ongoing investment in technology and
to distribution network models incorporate Liftomatic’s exclusive
Parrot-Beak® clamping mechanism, which Then and ...
personnel NOW
keeps us on the cutting edge
of gear manufacturing, providing the
JTEK T Toyoda Americas Corporation allows the operator to safely and securely
has announced the addition of Phillips grip the drum lip throughout the pick-up
highest quality gears to the world’s most
Corporation to their distribution net- and release process. demanding industries.
work. Phillips’ full-service, 45-person sales Liftomatic Material Handling, Inc. is
force and 98-person service team will sup- an acknowledged leader in the design and
port Toyoda customers in Virginia, North manufacture of drum handling equipment.
Carolina, South Carolina, Georgia, Alabama, Headquartered in Buffalo Grove, Illinois,
Southern Gear & Machine is celebrating
Tennessee, Arkansas, and the Florida Liftomatic maintains manufacturing, engi-
60 years of leading the way in custom
Panhandle. neering and sales facilities around the globe.
Having technical showrooms in five of Liftomatic sells products in more than 40 precision gear manufacturing. Our
the eight southeastern states served, Phillips countries and to more than 400 of the ongoing investment in technology and
stands by its mission to be the best resource Fortune 500 companies. personnel keeps us on the cutting edge
in manufacturing technology for Toyoda of gear manufacturing, providing the
CNC owners. For more than 50 years, the MORE INFO www.liftomatic.com
highest quality gears to the world’s most
company has built a dedicated fleet of expert
staff vested in continuous improvement of CALL US TODAY TO FIND
demanding industries.
high performance results on a localized Brian Papke inducted OUT HOW WE
CALL CAN HELP
into Northern Kentucky
level. In addition to carrying JTEKT Toyoda US TODAY TO FIND
America’s entire line of CNC machines
WITH YOUR PRECISION
OUT HOW WE CAN HELP
(horizontal and vertical machining centers,
Business Hall of Fame WITH YOUR PRECISION
bridge-type mills, turning centers, grind- GEARGEAR
NEEDS!
NEEDS!
ing machines, and automation solutions), Brian Papke, chairman of manufacturing
Phillips offers engineering and application technology leader Mazak Corporation, has
SOUTHERN GEAR & MACHINE, INC.
support. JTEKT Toyoda Americas looks for- been inducted into the Northern Kentucky
3685 NW 106 Street
ward to working with the entire team at Business Hall of Fame. He accepted the Miami, Florida 33147
Phillips Corporation throughout their new award in April at the Metropolitan Club in (305) 691-6300
endeavors carrying Toyoda and Takisawa Covington, Kentucky, where he delivered (800) 248-5152
www.southerngear.net
Taiwan machining centers. remarks that credited Mazak’s customers [email protected]
and its employees for the company’s decades
MORE INFO www.phillipscorp.com of success across North America. Cutting Edge Technology in Experienced Hands
www.toyoda.com “Our customers are not just customers,
SoGearMarch2017GearSolutions.indd 1 2/20/17 15
June 2018      8:52:41 AM
INDUSTRY
NEWS

they are friends, and the majority of our plant as it became an 800,000-square-foot
employees are homegrown,” Papke said. campus and significant regional employer.
“We have all worked together over the years Today, the Kentucky facility serves as a proof
to create wonderful opportunities for fam- of concept for the Mazak iSMART Factory™
ilies, the local community, and all of the model in addition to acting as the stag-
areas our customers call home.” ing ground for some of the industry’s most
Under Papke’s direction, Mazak has strived advanced manufacturing systems, includ-
to give back to its customers and the manufac- ing innovative full 5-axis, Multi- Tasking and
turing industry through its contributions to HYBRID Multi-Tasking machines.
the state’s economic growth and its establish- Of course, Papke has also served the
ment of a successful model for manufactur- state and the manufacturing industry by
ing excellence. He also oversaw the Kentucky working to meet the needs of his company’s

Why ETC?
Brian Papke, chairman of Mazak Corporation, gives
his acceptance speech after receiving the Northern
Kentucky Hall of Fame award. (Courtesy: Cincy
NEW and RECONDITIONED
Magazine)
CUTTER BODIES for Sale.

customers since he joined the company in

1987. “One of Brian’s greatest traits is that
he listens,” said Paul Hemmer, president
of Paul Hemmer Company, a local leading
construction company that often works
with Mazak. “He listens to his staff and he
listens to his customers.” And armed with
that information, Papke and the team at
Mazak have developed revolutionary ideas
that have helped propel U.S. manufacturing
into the 21st century.
Today, North American manufacturers in
all types of industries use the Mazak iSMART
Factory model, which the company estab-
lished to better serve its customers and help

Customer Service, Speed, Quality, & Value

deliver the advanced technology for which
the company has become known. It is this
technology that has helped Mazak custom-

ETC
ers maintain their competitiveness and suc-
Choose the stick that works, cess to keep work and jobs from going off-
cause work doesn’t stop! shore, one of Papke’s personal goals for the
industry he has helped to lead for decades.
Commissioned by NK Y Magazine in
2710 West Caro Rd. partnership with the Northern Kentucky
Caro, MI 48723 Engineered Tools Corporation
Chamber of Commerce, the Northern
Phone: (989) 673-8733 Complete line of Bevel Gear Tooling Kentucky Business Hall of Fame celebrates
1307 E. Maple Rd., Suite “G” Cutter Body Reconditioning to O.E.M. Specifications Northern Kentucky’s heritage of business
Troy, MI 48083 Cutter Body Maintenance Program
accomplishments. The award honors men
Phone: (248) 619-1616 Precise Wire EDM Forms for Stick Blades
and women who have made a lasting con-
tribution to the community in economic,
cultural and civic endeavors. 
engineeredtools.com
MORE INFO www.mazakusa.com
16     gearsolutions.com
 American Mary Ellen
Jenny
AGMA
Blackford
Doran
Vice President
Directorof
Gear Manufacturers Communications
of Emerging
AGMA
Technology
Association

New AGMA committee offers

the latest on emerging technology

W
hether you call it Industry 4.0, the next industrial with the creation of the first Emerging Technology Pavilion at Gear
revolution, or smart manufacturing, it is here, and it Expo, which led to finding more experts to present on our four top-
will have an impact on you and your company. There ics of focus at AGMA events. We have provided expert presenters
has been a seismic shift in our culture brought on by for members for their on-site education events, and most recently, I
the increased availability of affordable high-speed computing power. moderated the robotics panel discussion at the 2018 AGMA/ABMA
It has allowed for the creation of new technologies. We can feel it Annual Meeting in Naples, Florida. We are working on roundtable
even in our daily lives. In our businesses, we see it in new tools such discussions for the upcoming SRN, and the committee will assist
as generative design, digital twin, preventive maintenance, supply with a presentation at the FTM. The ETC will continue to provide
chain management, and new material discoveries at the nano-level member access to experts in emerging technologies.
— pushing on manufacturing from all sides. The ETC provides information from the news each week in mul-
The AGMA Emerging Technology Committee (ETC) recognizes the tiple areas. On Tuesdays, we issue the Gear Industry Update, a weekly
new pressures faced by members and is working to help make sense overview of the important articles of interest to our members. Many
of the deluge of information. The com- emerging technology news items are
mittee, with the direction of the Board included in this e-newsletter every
of Directors, has spent its first six Wednesday in the Tech Deck on the
months focused on four specific areas: AGMA website, where we present the
the Industrial Internet of Things (IoT), most relevant developments from the
metal 3D printing, robotics & automa- four AGMA ETC focus areas. You may
tion, and new materials. The goal of sign up to receive the newsletter on the
the committee is to identify, investi- AGMA home page and visit the emerg-
gate, and inform AGMA members of ing technology section of the AGMA
Emerging Technologies that may dis- website to learn more.
rupt or significantly make an impact In coming months, you can look
on our industry, as well as to equip our forward to seeing more information
members with the information they from the ETC. We are working to pro-
need to succeed in this environment. vide a report on the current state of
After gaining a better understanding gear research and production by metal
of each of these areas, we have been working to create informational 3D printing and additive/subtractive processes. We are gathering
pieces providing a roadmap on how to implement these technologies information on materials research and how high-speed computing is
into our members’ business plans and onto factory floors. The ETC being used to create materials and increase efficiency in traditional
wants to be the microscope into understanding these technologies. material development. We are monitoring current research and will
The ETC is focused both on understanding and implementing bring you information on developments in light weighting, strength,
new technology and how AGMA members can gain new business new alloys, and new discoveries. The committee has 13 members
from these technologies. Robotics is an excellent example. In just from within the AGMA membership and is chaired by Brian Schultz,
the last couple of years, the barriers for bringing automation into president of Great Lakes Industry. We are soliciting support from
a plant have significantly decreased — it is no longer the case that experts to sit on Technical Advisory Groups (T.A.G.s) for each of the
robots are only used in automobile assembly lines or multi-billion- four focus areas.
dollar corporations. Technologies are now available for use across the From smart factories and smart products to predictive mainte-
manufacturing sector. As a result, there will be a natural increase in nance and generative design, AGMA will help you navigate technol-
the production of robots. The ETC is pursuing ways to help members ogy, security, and supply chain implications for your company, your
identify opportunities in the supply chain for this new level of pro- products, and your end users. I encourage you to stay informed with
duction and maximize production capability of their factory floors us and even join the ETC if you are interested.
through automation. Membership in the AGMA Emerging Technology Committee is
The ETC will seek out best practices and use cases for AGMA mem- available for all AGMA member companies. Please contact Mary Ellen
bers. The committee was able to have some early successes last year Doran at [email protected] for more information.
June 2018     17
AGMA/ABMA annual meeting was a great success

AGMA board of directors

The 2018 AGMA/ABMA annual meeting was a great success on many

levels. There were 264 attendees at this year’s meeting, and 23 of
them were first-timers.
The AGMA Foundation Golf Tournament raised more than $8,500
for future scholarships. The First Annual Cornhole Tournament pro-
vided a new, fun way to network. Members got a chance to talk, relax,
and enjoy a little friendly competition in the sun. Photos from the
week are available to those who attended. Please contact brinkley@
agma.org to receive the link.
And, what a speaker lineup! From international trade breakdowns
to motivational speeches, members were presented with all facets of Maeve McGoff Benjamin Sheen
the industry and business. Some of the presentations are available
for download on the annual meeting webpage. admiration and respect of peers. For full press releases, please visit:
Thank you for making this annual meeting a memorable expe- www.agma.org/resources/newsroom/press-releases/
rience. We look forward to seeing everyone again next year in
Scottsdale, Arizona. AGMA ANNOUNCES NEXT GENERATION AWARDS
AGMA announced two recipients for this year’s Next Generation
AGMA GIVES TWO LIFETIME ACHIEVEMENT AWARDS Award. Maeve McGoff, sales & marketing coordinator at Cincinnati
AGMA presented David Goodfellow, president of Star SU and Sam Gearing Systems and Benjamin Sheen with Eaton-Vehicle, won the
Haines, CFO and chairman of Gear Motions, with the AGMA Lifetime award, and the announcement was made during the annual meet-
Achievement award. This award is presented to someone who has ing in Naples.
demonstrated dedication and leadership for the advancement of the This award is presented to someone who, while early in their
gear industry and AGMA, exemplified superior vision and exception- career, is an emerging contributor, innovator, and leader in the
al knowledge that has been shared with colleagues, and achieved gear industry. A Next Generation award recipient demonstrates

American
Gear Manufacturers
Association
18     gearsolutions.com
 Linda and Bipin Doshi Upcoming Courses
donated $100,000.

INTERNATIONAL COURSE WITH TOUR! GEAR

MANUFACTURING AND INSPECTION
July 10-12, 2018 | Ontario, Canada
Learn key factors in the inspection process that lead to better
design of gears. Develop a broad understanding of the methods
used to manufacture and inspect gears. Discover how the
resulting information can be applied and interpreted in the
design process.
This course is accompanied by a tour of a gear manufacturer.
The tour for 2018 will be at Ontario Drive and Gear.

BASIC TRAINING FOR GEAR MANUFACTURING

September 11-14, 2018 | Chicago, Illinois
Learn the fundamentals of gear manufacturing in this hands-on
course. Gain an understanding of gearing and nomenclature,
principles of inspection, gear manufacturing methods, hobbing
and shaping. Using manual machines, develop a deeper breadth
of perspective and understanding of the process and physics of
making a gear as well as the ability to apply this knowledge in
working with CNC equipment commonly in use.

FUNDAMENTALS OF WORM & CROSSED AXIAL

HELICAL GEARING
September 20-21, 2018 | Alexandria, Virginia (Come to AGMA
Jack Masseth Headquarters!)
received AGMA’s
Chairman’s Award Provides an introduction and emphasizes the differences
between parallel (the experience base) axis and worm and
crossed axis helical gears. Describe the basics of worm and
crossed axis helical gears, their fundamental design principals,
hard work and acts as a role model for others while having a posi- application guidelines and recommendations, lubrication
tive impact on AGMA. requirement, a discussion of accuracy and quality, and
summarize with a brief review of common failure modes.
AGMA FOUNDATION RECEIVES DONATION
TO ENDOW NEW SCHOLARSHIP
The AGMA Foundation received a $100,000 donation from Linda and
Bipin Doshi, formerly of Schafer Industries. The announcement to
endow a scholarship award through the AGMA Foundation was made
to members at the 2018 AGMA/ABMA Annual Meeting. The $100,000
donation is the largest single gift received in the AGMA Foundation’s
22-year history. The Doshis have been active leaders with AGMA and
AGMA Foundation boards for many years.

AGMA PRESENTS CHAIRMAN’S AWARD

AT ANNUAL MEETING
AGMA presented Jack Masseth of Meritor, Inc., with the AGMA
Chairman’s Award during the AGMA/ABMA annual meeting in Naples,
Florida. This award is presented to a recipient that has contributed
greatly to the gear industry and has gone above and beyond the call of
duty to support innovation and advancement through AGMA.

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

1001 N. Fairfax Street | Suite 500 | Alexandria, VA 22314 | (703) 684-0211 | www.agma.org
June 2018     19
 CALENDAR OF EVENTS
Whether you’re looking for technical education, networking opportunities, or a way for your voice to be heard
in the standards process, AGMA has something to offer you. If you would like more information on any of the
following events, visit www.agma.org or send an email to [email protected].

June 15 — Sound & Vibration Committee — WebEx

June 20 — Helical Gear Rating Committee — WebEx
June 26 — Nomenclature Committee — WebEx
JUNE

June 26–27 — Plastics Committee Meeting — Detroit, Michigan

June 28 — Gear Accuracy Committee Meeting — WebEx
June 29 — Computer Programming Committee — WebEx

July 10 — Wind Turbine Gear Committee — WebEx

July 10–12 — Gear Manufacturing and Inspection — West Waterloo, Ontario, Canada
July 13 — Emerging Technology Committee Meeting — WebEx
JULY

July 17 — Helical Gear Rating Committee — WebEx

July 19 — Lubrication Committee Meeting — WebEx
July 20 — Sound & Vibration Committee — WebEx
July 31 — Fine-Pitch Gearing Committee Meeting — WebEx
AUGUST

August 10 — Emerging Technology Committee Meeting — WebEx

AGMA LEADERSHIP

Jim Bregi: Chairman Nitin Chaphalkar: DMG Mori USA

EXECUTIVE COMMITTEE

Doppler Gear Company

Michael Engesser: Reishauer Corporation
John Cross: Treasurer
ASI Technologies Inc. Bent Hervard: CFT
BOARD OF DIRECTORS

John E. Grazia: Chairman, BMEC Michael McKernin: Circle Gear and Machine Company
GearTec Inc.
Todd Praneis: Chairman, TDEC Scott Miller: Caterpillar, Inc.
Cotta Transmission Company, LLC Gary Neidig: ITAMCO
Dean Burrows: Chairman Emeritus
Gear Motions Inc. Shawn O’Brien: McInnes Rolled Rings
Cory Ooyen: Global Gear & Machining, LLC
Matt Croson: President
Carl D. Rapp: The Timken Company
Amir Aboutaleb: Vice President, Technical Division
STAFF

Jenny Blackford: Vice President, Marketing Tania Sabados: Rapid Gear

Jill Johnson: Director, Member Services Greg Schulte: Bonfiglioli USA
Casandra D. Blassingame: Director, Education Hastings Wyman: Klingelnberg America, Inc.
General requests: [email protected] | Membership questions: [email protected] | Gear Expo information: [email protected]
Technical/Standards information: [email protected] | AGMA Foundation: [email protected]
20     gearsolutions.com
SMALLEST FOOTPRINT.
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kapp-niles.com [email protected] (303) 447-1130
June 2018     21
 MATERIALS E. BUDDY DAMM

MATTER
STEEL SOLUTION SCIENTIEST   
  TIMKENSTEEL CORPOR ATION

Increasing gear set power density

High-strength, high-toughness steels can be
used to increase power density while addressing
critical components of gear set design.

I ncreasing the power density of your gear sets allows you to develop
durable gear sets with an existing design but higher horsepower
and torque capabilities or with the same capacity, but reduced gear
size and mass for light weighting.
Increasing power density can be achieved by addressing three
critical components of gear set design: geometry, surface finish, and
metallurgy. By modifying geometry, one can avoid stress concen-
trations arising from geometric factors. Improving surface finish
through grinding, honing, or super finishing improves resistance
to root-bending fatigue, pitting fatigue, and scuffing damage. The
metallurgical tactics include the use of clean steels as discussed in
last month’s Materials Matter column, removal of intergranular oxi-
dation formed during heat treatment by grinding, shot peening gear Figure 1: Fatigue limit predicted from linear elastic fracture mechanics
roots to generate compressive residual stresses, and optimization of approaches described in extensive work by Murakami and colleagues assessing
case depth and heat treatment. the effect of small flaws such as inclusions on fatigue strength.
This Materials Matter column focuses on employing affordable
higher strength steels in order to increase fatigue strength, wear
resistance, and resistance to bending overload damage. One of the
tremendous advantages steels have over other materials is the broad
range of strengths they can achieve by changing the chemistry and
heat-treatment process. Finding stronger steels than those typically
used for gears is not too difficult. What is challenging is getting
significantly stronger steels that exhibit sufficient toughness to
avoid brittle or ductile overload fractures or early fatigue failures in
gear sets subjected to high loads and/or transient loads. The classical
trade-off in all materials is that increasing strength nearly always
results in reduced toughness, but with careful design and processing,
steels can achieve significant strength improvement and still display
excellent toughness properties.
To assess fatigue strength and toughness, one needs only to look
for commonly available data on steel properties. An engineering
approximation can be made that the fatigue strength is conserva-
tively estimated to be 50 percent of the ultimate tensile strength.
And, the most common method to assess toughness is the Charpy
V-notch impact toughness test. Figure 2 shows the range of estimated
fatigue strengths and impact toughness combinations achievable by Figure 2: Area charts demonstrating the range of fatigue strength and Charpy
common gear steels (8620, 4320, 4820, 9310, 3310) and compares that impact energy (toughness) combinations achieved with typical (8620, 3310,
to some available, patent-pending, high-strength, high-toughness 4820, 4620, 9310) gear steels (grey shading) and affordable, patent pending,
gear steels. In some cases, a 50 percent increase in fatigue strength high strength, high toughness steels for gears (blue shading). The vertical lines
can be achieved with good, and sometimes even better, toughness represent the fatigue strength used to compare these two alloy types below.
than the more common gear steels.
It is worthwhile to take a moment to consider how higher strength includes, among other details, more precise and design-relevant
steels further drive the need for clean steels. The AGMA Metallurgy metrics for steel cleanness as described in the January 2017 fea-
and Materials committee has been revising the “AGMA Information tured article “Gear Design Relevant Steel Cleanness Metrics,” and
Sheet 923 — Metallurgical Specifications for Steel Gearing.” The in April 2017’s “Steel Cleanness and Why Measurement Matters,”
addition of a grade 4 steel for gearing has been proposed, which May 2017’s “Industry Standards for Steel Cleanness,” and June 2017’s
22     gearsolutions.com
 One of the tremendous advantages steels have over other materials
is the broad range of strengths they can achieve by changing the
chemistry and heat-treatment process.
“Power Density; Why Clean Steel Matter” Materials Matter articles.
Figure 1 describes the relationship between inclusion size and steel
fatigue strength based on the extensive work of Murakami and col-
leagues, wherein they found that fatigue strength was related to the
square root area of an inclusion perpendicular to the principal stress
direction as described by Equation 1. As steel strength is increased
and gears are subjected to higher loads, the critical flaw size that
limits the fatigue strength goes down. As our industry adopts higher
strength steels to improve the capacity of advanced gear sets, having
clean steels becomes increasingly important.

EQUATION 1

Where ∆Kth is the threshold, or minimum stress intensity required

for fatigue crack growth and represents the square root area
of an inclusion-assessed perpendicular to the principal stress.
In order to assess the magnitude of the potential for either light
weighting or increased power throughput, one needs to assess the
effects of traditional versus high-strength, high-toughness gear Figure 3: Assuming an increase in fatigue strength from 75 to 110 KSI results
steels on gear set design. The Technical Resource “ANSI/AGMA 2001- in a 45-percent increase in gear set horsepower capacity. Relative horsepower
D04, Fundamental Rating Factors and Calculation Methods for capacity (as a percentage) as a function of the bending fatigue strength
Involute Spur and Helical Gear Teeth” provides a framework and calculated per the AGMA 2001-D04 technical resource.
the equations necessary to make such estimates. In table 4 of this
AGMA resource, the allowable bending stress for grade 3 gears is
listed at 75 KSI. This value also is shown as the AGMA limit in Figure
1. The allowable limit for high-strength, high-toughness steels also
is shown in Figure 1 at 110 KSI. In each case, for traditional and for
high-strength, high-toughness gear steels, the actual fatigue capacity
may be measurably higher than these conservative limits and will be
further dependent on the steel grade and heat-treatment processes
selected. For the sake of illustration, the bending stress fatigue limits
of 75 KSI and 110 KSI were selected for further calculations.
A generic pinion and gear set was conceived, and the calculations
for this gear set were built in a spreadsheet in order to assess the
magnitude of potential benefits.
Figures 3 and 4 show the results of these calculations. The switch
from commonly used gear steels to high-strength, high-toughness
gear steels can result in a 45-percent horsepower increase in an
increased through-put initiative or a 30-percent weight reduction in
a light weighting initiative. When you need to design your gear sets
to go beyond typical gear performance expectations, high-strength,
high-toughness gear steels can help get you there. Collaboration
between gear designers and materials designers will continue to
drive improvements in our industry.  Figure 4: Assuming an increase in fatigue strength from 75 to 110 KSI results in a
30-percent reduction in gear set mass. Relative gear set mass (as a percentage)
Editor’s note: This article originally appeared in the August 2017 issue as a function of the bending fatigue strength calculated per the AGMA 2001-D04
of Gear Solutions magazine. technical resource.

ABOUT THE AUTHOR

E. Buddy Damm is a scientist–advanced steel solutions at TimkenSteel Corporation. He is responsible for developing new or improved products
for the company’s customers and new or improved processes for its manufacturing operations. His responsibilities include technical leadership for
TimkenSteel’s high-strength, high-toughness steels innovation platform and corrosion-resistant steels innovation platform. Damm holds a bachelor’s
degree in metallurgical engineering from Michigan Technological University and a master’s and a doctorate degree in material science and
engineering from Colorado School of Mines. He can be reached at [email protected]. Learn more at www.timkensteel.com.

June 2018     23
 TOOTH BRIAN DENGEL

TIPS GENER AL MANAGER   KHK-USA

Worms and worm wheels – a primer

Worm gear pairs are an excellent design choice is known as a single enveloping set. It is designated as such because
there is only one set of threads on the worm that engage the teeth
when you need to reduce speeds and change on the worm wheel. Because the worm pair is a friction drive and
the directions of your motion, and they have one set of threads repeatedly engages the worm gear, the material
of the worm needs to be significantly harder than that of the wheel.
many other applications as well. For this reason, worms are typically produced from steel and worm
wheels are typically produced from bronze alloys. It is common to

F irst published in 1973, the novel How to Eat Fried Worms by Thomas
Rockwell tells the story of Billy and his desire to win a bet by eating
a worm a day for 15 days. Although the thought of eating worms is
harden and grind worms specifically when they are going to be used
under high load or operating at high speeds such as inside a reduc-
tion drive gearbox.
not something most of us would consider doing, Billy finds a way to Another type of worm gear set is the double enveloping pair. In
ingest a nightcrawler each day. Much like this children’s story, most this set, the worm is not straight but has a concave tooth shape which
mechanical engineers know about worms, but are not comfortable matches the curvature of the worm wheel. This permits more of the
designing them into their systems. threads of the worm to engage with the worm wheel. This additional
Worm pairs or worm drives are interchangeable terms for a set contact allows for greater torque transmission.
of mechanical components that consist of a A third type of worm gear set is the
worm and a worm wheel. The worm is the duplex pair. This type of worm pair uses a
drive mechanism in this set and has a shape single enveloping worm which has a variable
like that of a screw. The worm has several pitch across its length. As the pitch profile
critical dimensions which define how it will changes, the tooth form is increased, and
function in the set. The critical values are the backlash is decreased. Using this type of
the outside diameter of the worm, the lead worm gear pair, a near-zero backlash worm
angle of the threads, the direction of the gear assembly can be produced (Figure 1).
threads, and the number of starts of the Other variations of worm gearing that
threads. For the worm shown, the thread have been developed to reduce backlash
direction is clockwise; this corresponds include the use of a spring loaded, split worm
to a right-hand thread. Although available (known as the Ott worm), or the use of spring
Worm drive
in both left-hand and right-hand threads, loaded windows in the worm gear.
the right-hand thread is the most common Worm gear pairs are friction drive mech-
choice. This worm also has two starts to the anisms. As such, they require lubrication to
threads. This is important in determining remove the heat built up by friction. Due
the reduction ratio of the pair. to the limits of most lubricating fluids,
The worm wheel, also known as the the input speed of the worm needs to be
worm gear, is simplistically a helical gear less than 1800 rpm. At higher speeds, most
that matches the pitch, pressure angle, lubricants do not have the ability to pull the
and helix angle of the worm. The signifi- heat from the mesh and will froth inside
cant difference between a worm gear and a the gearbox. In most cases, open worm gear-
helical gear is the throat. This is an indent ing should be lubricated with recirculating
in the tooth form that allows the worm to splash lubrication. However, when enclosed
be properly seated with the centerline of in a housing, the suggestions in Figure 2
the worm wheel. The speed ratio of a worm should be followed.
gear pair is determined by the number of Due to the friction, some designers will
teeth on the worm wheel and the number choose a worm gear pair to act as a brake to
of thread starts on the worm. For worms Worm wheel prohibit reversing motion in their mecha-
with a single thread, very high-speed ratios nism. This idea develops from the concept
can be developed. Since the speed ratio is the ratio of the number that a worm gear pair becomes self-locking when the lead angle is
of teeth to the number of thread starts, it is possible to change small and the coefficient of friction between the materials is high.
the reduction ratio by replacing the worm pair with another set Although not an absolute, when the lead angle of a worm gear pair
which is produced with additional starts. With the addition of is less than 4 degrees and the coefficient of friction is greater than
more thread starts, the helix angle needs to increase if the center 0.07, a worm gear pair will self-lock.
distance is to remain the same. Since worm gears have a lead angle, they do produce thrust loads.
There are several types of worm gear pairs. The set detailed above These thrust loads vary on the direction of rotation of the worm and
24     gearsolutions.com
 gearbox. In most cases, open worm gearing should be lubricated w
enveloping worm whichHowever,
lubrication. has a variable
whenpitch across itsinlength.
enclosed As the the
a housing, pitchsuggestions
profile chan
tooth form is increased, and the backlash i
decreased. Using this type of worm gear p
zero backlash worm gear assembly can be
Other variations of worm gearing that hav
developed to reduce backlash include the u
spring loaded, split worm (known as the O
or the use of spring loaded windows in the
gear.
Figure 2: Worm gear lubrication when enclosed in a housing.

Worm gear pairs are friction drive mechan

wheel away from itself if operated counter-clockwise. A left-hand
Due to the friction, some designers willrequire
such, they chooselubrication
a worm to gear pair th
remove to
worm will act in the exact opposite manner.
Worm gear pairs are an excellent design choice when you need
reversing motion in their mechanism.
Figure 1: Worm gear backlash calculations.
This
built up by ideaDue
friction. develops fromofthe
to the limits m
to reduce speeds and change the directions of your motion. They
are available in infinite ratios by changing the number of teeth on
lubricating becomes
fluids, the self-locking
input speed of when the lead
the worm needsangle
to lessisthan
small and
1800 theAtcoeffici
rpm. higher
the worm wheel and, by changing the lead angle, you can adjust
for almost any center distance. I don’t recall what Billy did with his
most lubricants
the direction
materials due
of the threads. not have
is high.
A right-hand worm the ability
Although
will pull the wormto pull the heat from the mesh and will froth in
not an absolute, when the lead angle of
$50 for eating all 15 worms, but I do know I won’t be taking up that
wheel toward itself if operated clockwise and will push the worm challenge any time soon. 
gearbox. 4 Indegrees
most cases, andopen the worm
coefficientgearingof should be lubricated
friction is greaterwith recirculating
than spl
0.07, a worm
lubrication. However, when enclosed in a housing, the suggestions below should be fo
ABOUT THE AUTHOR Brian Dengel is general manager of KHK-USA, which is based in Mineola, New York. Go online to www.khkgears.us

Since worm gears have a lead angle, they do produce thrust loads.
direction of rotation of the worm and the direction of the threads. A
Analytical Gear Inspection
Win the worm wheel towards itself if operated clockwise and will push
DOB/DOP Gages
dow
itself
s10 it operated counter-clockwise. A left-hand worm Double Flankwill act in t
Testers
64
Bit
OS PGM 165 Gear Burnishing Machines
-M Gear Deburring Machines
inim Master Gears
al O
per
ato Gea Spline Gauges
r
Due to the friction, some designers willrachoose
T rMa worm gear pair toMetrology
act as aServices
brake to pr
inin
gR eas
reversing motion in their mechanism. This ideaeqdevelops ure
from the concept
REPOWERED that a worm
Gear Inspection
uire
d- men Machines
t Sy
becomes self-locking when the lead angle is small andInthe tuit coefficient of friction betwe
materials is high. Although not an absolute, whensthe
Contract Inspection
temlead iangle
ve U of a worm gear pair is
ser
s Frie
4 degrees and the coefficient of friction is greater than 0.07, a worm gear
n dly pair will self
Sof
twa
PGM 400 re
Since worm gears have a lead angle, they do produce thrust loads. These thrust loads v
direction of rotation of the worm and the direction of the threads. A right-hand worm w
the worm wheel towards itself if operated clockwise and will push the worm wheel aw
Penta Gear Metrology [email protected] www.pentagear.com (937) 660-8182
itself it operated counter-clockwise. A left-hand worm will act in the exact opposite m

PentaGearAD_GT__012018.indd 1 1/12/2018 1:14:17 PM

June 2018     25
Endothermic atmospheres used for heat treating

HOT
Why keeping CO content of a furnace must D. beSCOTT
stable MACKENZIE,
at a value of 20 PH.D.,percent FASM is critical for

SEAT
SENIOR RESEARCH SCIENTIST–METALLURGY   
accurate carbon control of the endothermic atmosphere.
HOUGHTON INTERNATIONAL INC.
Endothermic atmospheres used for heat treating
D. Scott MacKenzie, Ph.D., FASM
Why keeping CO content of a furnace must be stable at a value of 20 percent is critical for
Houghtoncarbon
accurate International,
control Inc. of the endothermic atmosphere.
Endothermic atmospheres used for heat treating
D. Scott MacKenzie, Ph.D.,part
During heat treatment, the FASM experiences different temperature regimes (Figure ). Atmospheres
Endothermic atmospheres used for heat treating
Whyused
are keeping
in heat
Houghtoncarbon
accurate
austenitizing.
COtreating
contenttoofprotect
International,
Thecontrol Inc.
a furnace
of the endothermic
atmospheres
the must
range from simple
be stable
part from scaling
atmosphere.
at aatvalue of 20 percent
the elevated is critical
temperatures
wrapping the part in stainless steel or tantalum
used forduring

Why
foil
During
D. forkeeping
Scott small
heat COroom
tool
treatment,
MacKenzie, content
parts,
the
Ph.D., part oftoexperiences
FASM aprotective
furnaceatmospheres
must betemperature
different
is very important,
containing inert or(Figure
regimes
as this value
protective
potential in the carbon controller.
is used to determine the carbon
gases.
). Atmospheres
stable
are
On used at a value
in heat
an industrial
Houghton International,
scale,ofthese
treating 20 percent
to protect
protective theis partcritical
gassesfrom for
arescaling
usuallyatmixtures
the elevated temperatures
of carbon
For atmosphere
Inc. range from simple wrapping the part in stainless steel or tantalum
monoxide
generators, used during
(CO),
air and the hydrocarbon are mixed
austenitizing. The atmospheres
accurate
hydrogen
foil
Duringforare
(H
small
heat
carbon
2), nitrogen
tool room
treatment,
control
the
(N 2
parts,
), of the
carbon
parttoexperiences
endothermic
dioxide (CO
protective atmospheres
different
2) and trace amounts
and
containing
temperature
introduced
inert
regimes
of water
or
into a vapor.
retort. For
protective
(Figure ). as
These
gases.
nitrogen-methanol, the nitrogen
Atmospheres
gases produced using either endothermic generators with natural
and gas or
methanol arepropane
injected the carbon
directly into the furnace. For endother-
atmosphere.
are used
source, in heat
or injection
On an industrial treating to
directly
scale, theseinprotect the
the furnace
protective part
gassesfrom
using scaling
arenitrogen at
usually and the elevated
mic generators,
methanol
mixtures temperatures
the air:gas ratio
mixtures.
of carbon used
In this (CO),
monoxide during
for natural gas is typically 2.8 - 3.1
article,
austenitizing. The atmospheres range dioxide
from simple2wrapping (theoretical
the 2.4:1),
partforinthe
stainlesswhile for
steelof a generator
orThese
tantalum using propane, the air:gas
we are going
hydrogen to
2), discuss
nitrogen
(Htreatment, the
(N2formation
),experiences
carbon of endothermic
different(CO ) andatmospheres
traceratio
amounts of protection
water vapor. parts
D uring heat
foilregimes
during
gases forare
source,
small
or
tool room
austenitization.
produced
the part
usingparts,
(Figure 1). Atmospheres
injection directly
eitherto
in
are
the
protective
endothermic
temperature
atmospheres
generators
used in heat treating
furnace using
containing
with
to pro-
nitrogen and
retical
is 7.5 - 8.1
natural
methanol
inert
gasand
vales
(theoretical
orthose
or protective
propane
mixtures.
typically
In
7.2:1).
asgases.
this
the
The difference between the theo-
used carbon
in the shop are associated with
article,
On an industrial
tect the
[INSERT part from
FIGURE scale,
scaling1] these protective gasses are usually mixtures of carbon monoxide (CO), the mixture is a bit more
at the elevated temperatures used during reaction kinetics. For nitrogen-methanol,
we
hydrogen (H2), nitrogenthe
are going
austenitizing. Theto discuss
atmospheres
2formation
(Nrange
), carbon of endothermic
dioxide
from simple (CO2)the
wrapping atmospheres
and tracedifficult
part amounts for
as the protection
of water
methanol vapor.
is ofThese
a liquid. parts
To obtain the proper atmosphere,
Endothermic
during
in
gases are steel atmospheres
austenitization.
stainless or tantalum are
foil for commonly
small tool roomused during
parts, to the
protec- heat
thetreatment
produced using either endothermic generators with natural gas or propane as the carbontotal volume of steel.
will be It40%is used as aOne gallon of methanol dis-
nitrogen.
carrier
source, gas
tive atmospheres for
or FIGURE atmosphere
containing inert
injection directly additions
in the furnace for
or protective carburizing
gases.
using or
nitrogen carbonitriding. Using
sociates to form
andSCF
methanol
240an
mixtures. endothermic
standard
Inforthis
cubic feet of CO and H2, so for 1,000
article,
[INSERT
generator, either
On an industrial 1]these
natural
scale, gas or
protectivepropane gases is
areused. If
usually nitrogen-methanol
mixtures is
of atmosphereinjected in
needed the afurnace,
furnace, then 400 standard cubic feet
we are going
of carbon monoxide to discuss the formation
(CO), hydrogen of endothermic
(H2), nitrogen atmospheres
(N2), carbon diox- for is
of nitrogen the protection
required, and 600 of standard
parts cubic feet of CO and H2 are
then methanol
Endothermic is the
atmospheres carbonare source.
commonly The predominant
used during reactions for producing
the heatrequired.
treatment endothermic
of steel. It is used as gasa
during
ide (CO2),austenitization.
and trace amounts of water vapor. These gases are produced Therefore, 2.5 gallons per hour (600 SCF needed/240 SCF
are shown
carrier gas below:
for atmosphere additions for
using either endothermic generators with natural gas or propane as carburizing or carbonitriding. Using an endothermic
per gallon CH3OH = 2.5 gallons per hour) are needed.
[INSERT
generator, FIGURE
eitherornatural
the carbon source,
1] gas
injection or propane
directly is used.
in the furnace If nitrogen
using nitrogen-methanol is injected in the furnace,
then methanol
Endothermic
and methanol is the carbon
atmospheres
mixtures. In thisare source.
commonly
article, weThe predominant
discussreactions
usedtoduring
are going the for producing
the heat treatment endothermic
of steel. ItFormula gasa
is usedNatural
as Nitrogen-
Natural
are shown
formation Gas:
ofbelow:
carrier gas for atmosphere additions for carburizing or carbonitriding. Using an endothermic
endothermic atmospheres for the protection of parts
Gas Species Gas Propane
Methanol
during austenitization. Carbon Monoxide CO 20% 23% 20%
generator, either natural gas or propane is used. If nitrogen-methanol Hydrogen is injected in the H2 furnace, 40% 31% 40%
Endothermic atmospheres are commonly used during the heat
then methanol isItthe carbon source. The predominant reactions forDioxide
Carbon producing endothermic CO2 gas
0.30% 0.30% 0.30%
2𝐶𝐶𝐻𝐻$ + 𝑂𝑂
treatment
Natural of ' ↔ 2𝐶𝐶𝐶𝐶 + 4𝐻𝐻'
steel. is used as a carrier gas for atmosphere additions
are shownGas:
for carburizing below:
or carbonitriding. Using an endothermic generator,
Water Vapor H2 O < 0.1% < 0.1% < 0.1%
Methane CH4 < 0.1% - -
either natural gas or propane is used. If nitrogen-methanol is injected Propane C3 H8 - < 0.1% -
in the furnace, then methanol is the carbon source. The predominant
Propane:
2𝐶𝐶𝐻𝐻
Nitrogen N2 40% 46% 40%
$ + for
Natural
reactions 𝑂𝑂
Gas: ↔ 2𝐶𝐶𝐶𝐶 +
' producing 4𝐻𝐻'
endothermic gas are:
Table 1: Typical gas compositions from different hydrocarbons used for generating
endothermic atmospheres.
Natural Gas:
Propane: 1
2𝐶𝐶𝐻𝐻
𝐶𝐶 + 𝑂𝑂𝑂𝑂
* 𝐻𝐻+$ + ↔↔2𝐶𝐶𝐶𝐶
3𝐶𝐶𝐶𝐶++4𝐻𝐻
4𝐻𝐻
2 '' ''
ENDOTHERMIC GENERATORS
Propane: The endothermic generator, regardless whether used with natural

Propane: 1 gas or propane, consists of several important parts: the retort; cata-
𝐶𝐶* 𝐻𝐻+ + 𝑂𝑂' ↔ 3𝐶𝐶𝐶𝐶 + 4𝐻𝐻'
Methanol: lyst; heating method (gas or electric); insulation; shell, gas-safety
2 equipment; and temperature control. Automated gas control is often
Methanol: added (and recommended).
1 An endothermic atmosphere generator (Figure 2) is operated
2𝐶𝐶𝐻𝐻
𝐶𝐶* 𝐻𝐻+* 𝑂𝑂𝐻𝐻
Methanol:+ ↔ 𝑂𝑂 2𝐶𝐶𝐶𝐶 + 4𝐻𝐻
↔ 3𝐶𝐶𝐶𝐶 + '4𝐻𝐻'
2 ' at very high temperatures, typically 1,950°F (1,065°C) for natural
gas, and 2,050°F (1,120°C) for propane generators. To handle these
All of these methods produce an atmosphere containing CO and elevated temperatures, a high temperature, heat resisting alloy like
All
2𝐶𝐶𝐻𝐻 of𝑂𝑂𝐻𝐻
these↔ methods
2𝐶𝐶𝐶𝐶 + produce
4𝐻𝐻 an atmosphere containinginCO and H2. Nitrogen appears because it
Methanol:
H .
2 * Nitrogen appears because
' it is either from the atmosphere HT is used. The retort is supported by a flange, and allowed to grow
is either from the atmosphere in the case of endothermic
the case of endothermic generators, or as a carrier gas in the case of generators,
in the vertical direction. Agas
or as a carrier in the of
schematic case
a small generator is shown
nitrogen-methanol atmospheres. The nominal composition of the in Figure 3.
All of𝑂𝑂𝐻𝐻
these
gas produced
2𝐶𝐶𝐻𝐻 ↔ methods
using theseproduce
2𝐶𝐶𝐶𝐶 of
+ CO
methods an
4𝐻𝐻produced
areatmosphere
shown in Tablecontaining
1. The differ- H2. Nitrogen
CO andInside the retort isappears because
the catalyst. it
This catalyst is often 1-inch cubes
ence *
in the amount ' using the different methods
is either from the atmosphere in the case of endothermic generators, or as a carrier gas in the case (MgO) cubes impreg-
of alumina impregnated with nickel. Magnesia

All of these methods produce an atmosphere containing CO and H2. Nitrogen appears because it
is either from the atmosphere in the case of endothermic generators, or as a carrier gas in the case

Figure 1: Typical sequence for heat treating, including carburizing.

26     gearsolutions.com
 The advantage of an oxygen probe, is that it is accurate and fast. A direct
read-out of the carbon potential of the atmosphere is common. The probe
has a high temperature range suitable for high temperature carburizing.
Little maintenance is required.
The retort is either heated using gas or electric heating elements. Radiant tubes are u
natural gas, and are prevent
hung vertically to reduce distortion, and to allow the thermal ex
the formation of soot in the temperature range of 1,300°F to
The retort istubes.
the radiant eitherElectric
heated using
heating gas or electric
elements
900°F (700°C - 500°C). Soot forms canheating
also beelements.
by the used. Typical
“carbon
Radiant tubes areco
reversal”temperature
reaction cu
natural gas, and
equipment, consistingare hung
CO of vertically
 Cthermocouples to reduce
+ CO2, in which soot distortion,
for process and
is formedtemperature, to allow
from the reaction the
excess thermal
temperatur
of carbon exp
the radiant tubes.
thermocouple, Electric
process heating
controllers,
monoxide to form elements
excess can also
temperature
carbon dioxide. beheat
These used. Typical
instrument
exchangers temperature
andcandata loggingco
either
equipment,
are usually consisting
included.be of thermocouples
water-cool, for Modern
or air-cooled. processpractice
temperature, excess temperature
is to use air-cooled heat
thermocouple, process controllers, excess temperature instrument and data logging e
exchangers.
If the retort is heated by natural gas, additional control equipment consisting of fire
are usually included. The retort is either heated using gas or electric heating elements.
equipment (manual Radiantshut-offtubes valve areorused
MSOV, fire-eyes
for natural andare
gas, and high-
hung and low-pressure
vertically to s
If the retortrequired
generally is heatedfor bysafe
reduce natural gas, and
gas operation.
distortion, additional
to The control
allowgas
thesupply equipment
thermal isexpansion
shut off consisting
the radi-of
(tripping
of thefire
M
equipment
event of any (manual shut-off
malfunction
ant tubes.suchvalveas: orheating
Electric MSOV, fire-eyes
elements canandalso high- and
be used. low-pressure
Typical tem- s
generally required for safe gas operation. The gas supply is shut off (tripping the MS
perature control equipment, consisting of thermocouples for process
event of any malfunction temperature,
such as: excess temperature control thermocouple, process con-
• Excess retorttrollers,
temperature.
excess temperature instrument and data logging equipment
• High gas pressure.are usually included.
•• Excess retort
Low gas pressure.temperature.
If the retort is heated by natural gas, additional control equipment
consisting of fire safety equipment (manual shut-off valve or MSOV,
•• High gas detected.
No pilot pressure.
fire-eyes and high- and low-pressure switches) are generally required
• Low gas pressure.
• Low retort temperature.
Figure 2: Three retort endothermic generator used to produce endothermic for safe gas operation. The gas supply is shut off (tripping the MSOV)
• No pilot detected.
atmospheres. (Courtesy: Surface Combustion, Inc., Maumee, Ohio.) in the event of any malfunction such as:
• Low retort temperature. Excess retort temperature.
Similar gas safety equipment High gas is used on the gas train supplying the retort with gas, s
pressure.
the temperature control gas supply.
 Low
 gas pressure.
Similar gas safety equipment No pilotis detected.
used on the gas train supplying the retort with gas, s
Atmosphere Control of  Generated
Low Gas
retort temperature.
the temperature control gas supply.
Similar gas safety equipment is used on the gas train supplying
The equilibrium composition of the gas depends on the water gas reaction:
Atmosphere Control theofretort
Generated Gas from the temperature control gas supply.
with gas, separate

The equilibrium composition

ATMOSPHEREof the CONTROL
gas depends OF on the water gas
GENERATED GASreaction:
𝐶𝐶𝐶𝐶 + 𝐻𝐻
The equilibrium composition 𝑂𝑂 ⇔ 𝐶𝐶𝑂𝑂 + 𝐻𝐻
'' of the gas''depends
'' on the water gas
reaction:
𝐶𝐶𝐶𝐶 + 𝐻𝐻' 𝑂𝑂 ⇔ 𝐶𝐶𝑂𝑂' + 𝐻𝐻'
This means that there are four gas species that can be used for proper control of the
Practically, there are really only two
This means thatreactions
there are fouravailable for control:
gas species that can be used for
This means that there are four gas species that can be used for proper
proper control of the atmosphere. Practically, there control
are really onlyof the
two reactions available for control:
Practically, there are really only two reactions available for control:
1
𝐶𝐶𝐶𝐶 + 𝑂𝑂'' ⇔ 𝐶𝐶𝑂𝑂''
2
1
𝐶𝐶𝐶𝐶 + 𝑂𝑂' ⇔ 𝐶𝐶𝑂𝑂 1
𝐻𝐻''𝑂𝑂 ⇔ 2 𝐻𝐻'' + 𝑂𝑂'''
Figure 3: Schematic representation of an endothermic generator showing general 2
assembly. Piping or flame safety equipment is not shown. 1
These two reactions 𝐻𝐻'are
𝑂𝑂 ⇔ 𝐻𝐻' + into
combined 𝑂𝑂'the water gas reaction
nated with nickel are often used with propane as the MgO resists heat above. From these last two reactions, that 2 means that we can control
better than alumina. Sometimes 1-inch spheres,These two reactions
impregnated with arefurnace
the combined into thebywater
atmosphere gas reaction
monitoring above. either
and controlling From the these las
reactions,
nickel are used, as the spheres offer a greater surface area. Nickel actsthat means water vapor in the atmosphere or by controlling the carbon dioxide. and
that we can control the furnace atmosphere by monitoring
as the catalyst to improve the kinetics of the natural These two
eithergasthe reactions
water vapor
or propane areincombined
Dewthepoint into the
atmosphere,
is often orwater
used gas reaction
bycontrol
to controlling theabove.
the carbon contentFrom
carbon these last
dioxide.
of atmo-
reactions,
reaction to form CO and H2. Plain refractory cubes are generally placed that means sphere generators or furnaces. However, the use of dew point instru- and
that we can control the furnace atmosphere by monitoring
Dewand point is often used tohas
control the carbonimplantation
content of of atmosphere generators or fu
f
at the air/gas mixture entrance to delay the reaction either the water vapor
preheat the in the
ments atmosphere,
waned with the or by controlling the carbon
more moderndioxide.
control
However,
gas to the operating temperature. Once at the operating temperature, the use of dew point instruments has waned with the implantation
methods such as carbon probes and infrared analyzers. The relation- of mor
the gas reacts with air to form the desired atmosphere Dew
controlpoint is oftensuch
methods,
composition. used
shipasto control
ofcarbon
dew point the
probes carbon
to the and content
infrared
percentage of atmosphere
of analyzers.
carbon The in
is shown generators
Figure 4. oroffud
relationship
Once the gas has reached the operating temperature However,
the percentagethe use
and of of
has dewthing
carbon
One point toinstruments
is shown in Figure
remember, ishas waned
. One
that thing
these with the only
implantation
to remember,
charts are valid that of
iswith more
athese c
reacted, the gas exits the generator, where it is controlimmediatelymethods,
passed such20 as carbon
percent CO.probes and infrared
Other charts need to be analyzers.
calculated The relationship
or developed for of d
through a heat exchanger to fix the composition theofpercentage
the gas, and of to carbon is shown inatFigure
CO concentrations values .other
Onethan
thing 20to remember,
percent CO. Theis that these c
classical
June 2018     27
 valid with a 20 percent CO. Other charts need to be calculated or developed fo
concentrations at values other than 20 percent CO. The classical dew point ins
ALNOR Dewpointer (Figure 1) – these instruments are commonly found in th
180
validare
They with
stilla 20
dew percent
inpoint
use today. CO. Other
instrument is thecharts
ALNORneed to be calculated
Dewpointer (Figure 5) ­—or developed
these
160
valid with a 20 percent CO. Other charts
concentrations at values other than 20 percent CO. The classical dew
instruments are commonly found need
in the to
heatbe calculated
treat shop. or
They developed
are point in f
1400 [INSERT
concentrationsFIGURE at 4]
values other than 20 percent
ALNOR Dewpointer (Figure 1) – these instruments are commonly found in
still in use today. CO. The classical dew point in
140
ALNOR
They areDewpointer
[INSERT stillThe
FIGURE amount
in use (Figure
5]today. of carbon1) –dioxide
these instruments
present in the are commonly
atmosphere is also found in t
They are still in use today.
used. This is often done using infrared analyzers. These often are
120

100
1500 The amountFIGURE
[INSERT of carbon
called three dioxide
4]gas analyzers.present in the atmosphere
The advantage of three gasisanalyzers,
also used. is This is o
[INSERT
infrared FIGURE
analyzers.
that the three 4] gases
These often are called
measured are three
CO, COgas 2, andanalyzers.
CH4. This The enables advantage
80
[INSERT FIGURE the user to5]
Depoint, °F

optimize the generator (or nitrogen-methanol system)

analyzers,
[INSERT is that the 5]
FIGURE three gases measured are CO, CO2 and CH4. This enable
60
The amount setting to first
of carbon(or achieve apresent
dioxide 20 percent CO. Once
in the that is accomplished,
atmosphere is also used. This isa
optimize histhegenerator nitrogen-methanol system) setting to first achieve
1600

40 The
Once amount
infrared of carbon
thatanalyzers.
charts
istionships
accomplished,
and
These dioxide
graphs
often
the present
indicating
are
charts called
andin the atmosphere
various
three
graphs
carbon
gas is various
analyzers.
indicating alsoThe
potential used.
rela- This is
advantage
carbon po
infrared analyzers. will accurately
These often are indicate
called carbon
three potential
gas analyzers.as a function
The advantage
20 analyzers, is
relationshipsofwill that
either the three
accurately
dew point or gases
indicate measured
carbon carbon are CO, CO and
dioxide. potential as a function of either d
2 CH 4. This enabl
analyzers,
optimize his is that the three
generator (or gases measured are system) CO, CO2 and CH . This enable
0 dioxide. The infrared gasnitrogen-methanol
analyzer operates by measuringsetting to 4first
the absorption achieve
1700
optimize
Once thathis
1800
of generator
is accomplished,
infrared (orthrough
light nitrogen-methanol
the charts
the gas and sample.graphssystem)
The setting
indicating
gases CO, to first
CO2,various
and achievep
CH4carbon
-20
The
Once infrared
that
relationships is gas
absorb
analyzer
1900
accomplished,
willlight
accurately operates
the charts
at specificindicate
by
wavelengths.
measuring
and
carbon graphs the absorption
indicating
potential
A detector
of infrared
the energyof eitherpo
various
as a function
measures carbon lig
sample. Thepresent
relationships gases
will CO, CO
accurately 2 and CH
indicate 4 absorb
carbon light
potentialat veryas specific
a function wavelength
of either d
dioxide.
-40
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 at the wavelength of interest and compares it to the refer-
1 1.1
% Carbonmeasures
dioxide. theenceenergy present
condition of no at the
absorption.wavelength
A typical of interest,
modern infraredand compares
analyzer it to
The
condition
Figure 4: Relationship of dew point to the carbon potential. These values are
infrared
ofisno gas
shown analyzer
in Figureoperates
absorption. 6. typicalby
A measuring
modern infraredthe absorption
analyzer isof infrared
shown in Fili
correct with a 20 percent CO concentration.
The infrared
sample. The gas
gases
The analyzer
CO,
relationshipCO operates
and
between
2 CH by
the4
measuring
absorb
carbon light
potentialtheat absorption
very
and specific
carbon of
dioxide infrared
wavelengt li
The relationship
sample.
measures Thethegases between
energy CO, the
CO2 and
present carbon CH
at isthe potential
4 absorb
wavelength
shown in Figure and
lightof carbon
at very
interest,
7. Again, dioxide
specific
it is and is shown
wavelength
compares
important in
it to
ismeasures
important toenergy
reiterate, that these graphs are only valid with 20compares
percent CO i
condition of no absorption. A typical modern infrared analyzer is shown intoF
the present at the
to wavelength
reiterate, that of
these interest,
graphs areandonly valid it
Use of other
condition of values of CO inAthe
no absorption. furnace
typical
with 20modern or generator
percent in theatmosphere
infrared
CO analyzer is Use
atmosphere. will
shown produc
in F
Theofrelationship
One the most recently betweendevelopedthe carbon
of other potential
methods
values of and
forCO incarbon
controlling
the furnace dioxide
furnace
or gen- isatmosphe
shown i
The
or relationship
iscarbon
important
probe. between
to reiterate,
In this method,the these
that carbon
thegraphs
erator potential
carbon
atmosphereare andwillcarbon
only
potential valid dioxide
with
is related
produce 20 is shown
percent
to the
erroneous COinp
oxygen
is important
Use of other
associated to
withvaluesreiterate, that these
of CO in reaction:
the reversible graphs are only valid
the furnace or generator atmosphere will produ
results. One of the most recentlywith 20
developedpercent CO
Use
Oneof ofother
the most values of COdeveloped
recently in themethods
furnace methods or controlling
for generator atmosphere
for controlling furnace atmo-
furnace willatmosph
produc
One of theprobe.
or carbon most recently developed
In this method, themethods
spheres is the for controlling
oxygen
carbon potential or carbon probe.
is related furnace
to theatmosph
In this
oxygen
or carbon probe. In this method,
associated with the reversible reaction: the
method, carbon potential
the carbon
1 is
potential related to
is related the
to oxygen
the oxygen 𝐶𝐶𝐶𝐶partial
⇔ pressure
𝑂𝑂 + 𝐶𝐶𝑂𝑂 associated with
associated with the reversible reaction: 2 ' '
the reversible reaction:
𝑝𝑝67
𝐾𝐾23 = 1 9
𝐶𝐶𝐶𝐶 ⇔ 1 𝑂𝑂 ' ' + 𝐶𝐶𝑂𝑂'
𝐶𝐶𝐶𝐶 ⇔ 2𝑝𝑝𝑂𝑂7'8 𝑝𝑝+67𝐶𝐶𝑂𝑂
2 𝑝𝑝67 8 '
[INSERT FIGURE 6] 𝐾𝐾23 = 9𝑝𝑝67
𝐾𝐾23 = 9'
[INSERT FIGURE 7] 𝑝𝑝7 𝑝𝑝678
𝑝𝑝7'88𝑝𝑝678
[INSERT FIGURE 6]
[INSERT FIGURE 6]
[INSERT FIGURE 7] 1
[INSERT FIGURE 7] %𝐶𝐶 ≈
<𝑝𝑝78
1
Figure 5: Classic ALNOR Dewpointer used to control carbon potential by the use of water vapor. %𝐶𝐶 ≈
In other words, 1
the carbon potential of
In other words, the carbon potential of the atmosphere
the atmosphere <𝑝𝑝7is
%𝐶𝐶is≈inversely inversely
8 related related to t
to the
𝑝𝑝pressure
<that
the partial pressure of oxygen. This squareagain assumes
root of the partial 78the CO content of the
of oxygen.
constant, and at approximately 20 Thispercent (23 percent
again assumes forCO
that the propane
contentgenerated
of a
In other words, the carbon potential of the atmosphere
the atmosphere is constant is and inversely
at approxi- related to
An
In oxygen
theother
partial probe
words,
pressureor carbon
the carbon
of probe
potential
oxygen. consists
mately
This of20the
again of platinum
atmosphere
percent
assumes thatelectrodes
(23 percentisthe
inversely
forCO separated
propane- related
content toby
of the
zirconia
the tube.
partialand The
pressure probe is inserted
of oxygen. This into the furnace
again assumes
generated atmospheres). or generator.
thatforthepropane An
CO content air suppl
of the
constant, at approximately 20 percent (23 percent generated
constant, and at approximately 20An oxygen
percent (23probe or carbon
percent probe con-
for propane generated
An oxygen probe or carbon probe sistsconsists
of platinum of platinum
electrodeselectrodes
separated by separated b
An oxygen probe or carbon probe consists
yttrium-doped of platinum
zirconia electrodes
zirconia tube. The probe is inserted into the furnace or generator. An air supp
an tube. The separated
probe b
zirconia tube. The probe is inserted into the
is inserted intofurnace
the furnaceor or
generator.
generator. AnAn air supp
air supply of approximately 0.5 CFH of air is
supplied to the probe as a reference. The dif-
ferential oxygen partial pressure between
the furnace atmosphere and the reference
atmosphere sets up a voltage across the
probe. By measuring this small voltage
(measured in millivolts), the carbon poten-
Figure 6: Modern multi-gas infrared analyzer. (Image of Ultramat 23 courtesy: Siemens Corporation.) tial can be determined. Thus, the furnace
28     gearsolutions.com
 3.0
The advantage of an oxygen probe, is that it is accurate and fast. A
direct read-out of the carbon potential of the atmosphere is common.
1500
2.5 The probe has a high temperature range suitable for high tempera-
ture carburizing. Little maintenance is required.
The primary disadvantage of the oxygen probe is that it assumes
2.0
a fixed CO content (typically either 20 percent for natural gas or 23
percent for propane). If the CO content is not at this fixed value, then
the readings obtained by the probe are erroneous. The oxygen probe
% CO2

1.5

1600 is also a ceramic tube and prone to thermal or mechanical shock. It

must be routinely replaced at roughly yearly intervals, depending on
1.0
the application. Heavy carburizing can shorten the life of the probe.
1700 However, the accuracy, ease of use and lack of maintenance, generally
0.5 outweigh the disadvantages.
1800
1900

0.0
CONCLUSION
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 In this article, we have discussed the production of endothermic
Carbon %
atmospheres used in the hardening of steel. We also discussed the
control of the carbon potential of the associated furnace or generated
Figure 7: Relationship between CO2 and carbon potential.
atmosphere. Probably the most important takeaway from this discus-
sion, is that the CO content of the furnace must be stable at a value of
atmosphere carbon potential can be controlled by air and natural 20 percent (or 23 percent for propane generators) for accurate carbon
gas additions by monitoring the voltage potential across the probe. control of the endothermic atmosphere. The use of a portable infra-
In modern instruments, this is done internally using microproces- red gas analyzer can make troubleshooting of atmosphere problems
sors. In many ways, it operates in a similar fashion to the O2 sensor much simpler and more accurate. Should you have any questions
in a car for proper combustion. regarding this article, please contact the writer. 

ABOUT THE AUTHOR D. Scott MacKenzie, Ph.D., FASM, is senior research scientist-metallurgy at Houghton International Inc. For more
information, go to www.houghtonintl.com.

Modular
Drawer
System

STOR-LOC MODULAR
DRAWER SYSTEM
880 N. Washington Ave. Kankakee, IL 60901
Toll Free: 1.800.786.7562
Fax: 1.800.315.8769
email: [email protected]

www.storloc.com

June 2018     29
ISSUE GEAR SHAPING / GEAR HOBBING
FOCUS

GEAR TOOTH STRENGTH

ANALYSIS OF
HIGH PRESSURE
ANGLE
CYLINDRICAL
GEARS

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria,
Virginia 22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the American Gear
Manufacturers Association. (AGMA) This paper was presented October 2017 at the AGMA Fall Technical Meeting in Columbus, Ohio. 17FTM03

30     gearsolutions.com
High pressure angle gears are not expected to show better
mechanical behavior in high power transmissions than
gears with conventional designs.
By Dr. ALFONSO FUENTES-AZNAR and Dr. IGNACIO GONZALEZ-PEREZ

T
he gear tooth strength of high pressure angle formance with similar bending and contact stresses
gears is studied and compared with that of con- over more traditional gear pressure angles. Also, it was
ventional pressure angle gears. The comparison stated that high pressure angle gears appeared to be
is carried out regarding contact pressure, con- better suited to the low-speed, high load, and grease-
tact and bending stresses, and the loaded function lubricated conditions.
of transmission errors. The gear geometric models In [3], a method for specifying gear teeth with
are generated by the computerized simulation of the higher pressure angles was presented. The idea of
manufacturing process, and the corresponding finite this work was to achieve higher bending and surface
element models consider a large number of contact contact strength or, in other words, to reduce bending
positions along two cycles of meshing. In this way, and surface contact stresses by using the highest as
the load sharing between different pairs of contact- possible pressure angle. Miller’s work [3] was directed
ing teeth is considered, and the evolution of contact to isolate the influence of the pressure angle on the
pressure, and contact and bending stresses all over the results so that he kept the number of teeth and module
cycle of meshing are obtained. In general, high pres- of all designs as constant. The proposed method in
sure angle spur and helical gears do not show a better [3] allowed for the determination of proper high-
behavior regarding contact pressure, contact stresses, pressure angles for which the gear met conditions on
and bending stresses than spur and helical gears with the desired top land, contact ratio, or hob tip radius.
traditional pressure angle of 25 degrees. Based on the Four designs were evaluated having the traditional
obtained results, high pressure angle gears are not 25-degree pressure angle, and three other designs
expected to show better mechanical behavior in high having pressure angles of 33.5, 35, and 36 degrees. In
power transmissions than gears with conventional the mentioned work, all data and stress calculations
designs. The results gathered from the finite element were performed using the AGMA GRS 3.1.7 Gear Rating
analysis are not in agreement with the improvement Suite program. The application of high pressure angle
on the pitting and bending behavior of the gears that gearing in low speeds, coarse pitch, and lower quality
were anticipated by using analytical models as pro- level was mentioned in [3] as typical applications for
vided by international standards. these gears. It was suggested that an alternative FEA
(Finite Element Analysis) should be performed on
1: INTRODUCTION the gear teeth and the results compared with those
The use of lower pressure angles in cylindrical gears published in the mentioned work. Miller’s work
has been decreasing over recent decades in favor of inspired the research work presented in this paper.
using higher pressure angles. Nowadays, it is uncom- In [4], it is stated that the lower the pressure angle,
mon to find new designs of cylindrical gear drives the higher the surface compressive and bending stress-
considering a pressure angle of 14.5 degrees because es become. In that work, high pressure angle gears are
it is broadly accepted that gears with higher pressure referred to as not as quiet as low pressure angle gears.
angles yield better mechanical behavior regarding The main reason is that the tooth deflection under
contact and bending stresses. Therefore, new designs load is very small for high pressure angle gears. Noise
of cylindrical gears consider pressure angles of either is generated when the load is transferred from one
20 degrees or 25 degrees. tooth to another upon impact [4]. Again, high pres-
The design of cylindrical gear drives with high pres- sure angle gears are considered to have a higher power
sure angles has attracted the attention of researchers density and are recommended for high horsepower
in the past. In [1, 2], the results of a study to determine transmissions [4].
the feasibility of using high pressure angle gears in The design of high pressure angle gears is chal-
aeronautics and space applications were presented. lenging because of the obtained geometry for the gear
The NASA GRC Spur Gear Test Facility was used for that teeth. The pointing of the gear teeth on the one hand
purpose. Pressure angles of 20, 25, and 35 degrees were and having enough tip edge radius for the cutting
considered in three different designs of spur gears. tools on the other hand are limiting factors for gear
The face width and center distance were deemed to designs considering high pressure angles. To avoid
be constant. However, the test specimens had a differ- those problems, asymmetric gears were proposed as
ent number of teeth and different modules. The con- a solution to increase the load capacity of gear drives
clusions of this study mentioned that high pressure while reducing their weight and dimensions [5]. In
angle spur gears running at high speed provided per- [6], the results of the comparison of several designs of
June 2018     31
asymmetric gear drives were presented. The application of high pres- diameter may influence the Von Mises stresses on the fillet area. For
sure angles, not only for the driving side of the gear teeth as tradition- this reason, the maximum principal stress in the fillet area (the larg-
ally is done but also for the coast side of the teeth was investigated. est tensile stress) is considered for comparison of bending stresses
In that work, it was mentioned that the maximum contact stresses among different gear designs.
and contact pressures on the gear teeth depend only on the pressure
angle of the contacting side (driving side) of the gear drive, no matter 3: AGMA’S APPROACH FOR THE EVALUATION
what the pressure angle of the coast side is. It was mentioned that OF CONTACT AND BENDING STRESSES
bending stresses were reduced when higher pressure angles are used, The American Gears Manufacturers Association (AGMA) has
not only for the coast side as stated in other works [7, 8] but also for developed and disseminated methodologies to design and analyze
the driving side. gear drives during the last hundred years. AGMA started in 1916 to
3 AGMA’s approach for the evaluation of contact and
This paper is intended to answer the following research ques- create standards that define gear types, tooth sizes, tolerances, and in
tion: Can we extend and recommend the use of pressure angles of The American
general, to set upGears Manufacturers
methodologies Association
to contribute to making(AGMA) has develo
gears safer
30 degrees or higher in symmetric gears to improve the mechani- and interchangeable even if manufactured in different
methodologies to design and analyze gear drives during the last hun locations or
cal behavior of cylindrical gear drives? The methodology to carry by different companies. The method presented in the AGMA 2101-D04
1916 to create standards that define gear types, tooth sizes, toleranc
out this research work is based on the application of finite element standard [9], Fundamental Rating Factors and Calculation Methods
analysis on models comprising of five pairs of contacting teeth, con-
methodologies to contribute to making gears safer and interchangea
for Involute Spur and Helical Gear Teeth, has been used in this work
sidering a very fine mesh on the contacting surfaces. Not only one locations
to assess the or performance
by different ofcompanies.
high pressureTheangle
method
gearspresented
according in the AG
point of contact will be considered for the analysis but the evolution Fundamental
to analytical methods. Rating The
Factors
AGMAand Calculation
2101-D04 standardMethods for Involute S
is the metric
of contact and bending stresses, contact pressure, and loaded func- used inofthis
edition AGMA work to assess
2001-D04. the performance
It provides the formulas of for
high pressure
rating the angle
tion of transmission errors along two complete cycles of meshing will methods. The AGMA 2101-D04 standard is the metric edition of AGM
pitting resistance and bending strength of spur and helical involute
be investigated. This perspective will provide a unique overview of gear teeth.for rating the pitting resistance and bending strength of spu
formulas
the mechanical behavior of high pressure angle gear drives and will The pitting resistance is considered a function of the Hertzian
be fundamental to provide further recommendations for the use of contact (compressive) stress, and for that, the well-known model of
The pitting resistance is considered a function of the Hertzian contac
gears with high pressure angles. contact between two cylinders is used as a basic model. The contact
the well-known
stress number sH model of contact
for cylindrical gearbetween two cylinders
teeth according to AGMAis[9]used as a
2: METHODOLOGY OF EVALUATION OF THE number
is 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻 for cylindrical gear teeth according to AGMA [9] is given
given by:
MECHANICAL BEHAVIOR OF CYLINDRICAL GEARS
The mechanical behavior of gear drives can be evaluated by using 𝐾𝐾𝐾𝐾𝐻𝐻𝐻𝐻 𝑍𝑍𝑍𝑍𝑅𝑅𝑅𝑅
analytical and pseudo-empirical methods as provided by internation- 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻 = 𝑍𝑍𝑍𝑍𝐸𝐸𝐸𝐸 �𝐹𝐹𝐹𝐹𝑡𝑡𝑡𝑡 𝐾𝐾𝐾𝐾𝑜𝑜𝑜𝑜 𝐾𝐾𝐾𝐾𝑣𝑣𝑣𝑣 𝐾𝐾𝐾𝐾𝑠𝑠𝑠𝑠
𝑑𝑑𝑑𝑑𝑤𝑤𝑤𝑤1 𝑏𝑏𝑏𝑏 𝑍𝑍𝑍𝑍𝐼𝐼𝐼𝐼
al standards (AGMA — American Gear Manufacturers Association, or
ISO — International Organization for Standardization) or numerical where
methods as the finite element method. AGMA and ISO provide a
methodology to evaluate the contact and bending stresses, and with 𝑍𝑍𝑍𝑍𝐸𝐸𝐸𝐸 is the elastic coefficient,
them, the safety factors against the risk of failure of the gear drive by
pitting or bending are calculated. On the other side, using the finite 𝐹𝐹𝐹𝐹𝑡𝑡𝑡𝑡 is the transmitted tangential load,
element method, the contact and bending stresses on the gear tooth
𝐾𝐾𝐾𝐾𝑜𝑜𝑜𝑜 is the overload factor,
can be determined, as well as the contact pressure, contact deforma-
tions, and tooth deflections that are taken into consideration for the 𝐾𝐾𝐾𝐾𝑣𝑣𝑣𝑣 is the dynamic factor,
determination of the loaded function of transmission errors.
Many researchers refer to contact stresses in technical publica- 𝐾𝐾𝐾𝐾𝑠𝑠𝑠𝑠 is the size factor,
tions, but many times, there is no mention to what they consider as
𝐾𝐾𝐾𝐾𝐻𝐻𝐻𝐻 is the load distribution factor,
contact stresses. Frequently, Von Mises stresses on the contact area,
contact pressure, or the minimum principal stress are considered 𝑍𝑍𝑍𝑍𝑅𝑅𝑅𝑅 is the surface condition factor for pitting resistance,
indicators of the contact stress, but they may sometimes yield to
different conclusions. 𝑏𝑏𝑏𝑏 is the net face width of narrowest member,
Regarding Von Mises stresses as an indicator of contact stress, due
to the fact that maximum Von Mises stresses occur underneath the
𝑍𝑍𝑍𝑍𝐼𝐼𝐼𝐼 is the geometry factor, and
contacting surfaces, they are difficult to capture in a finite element 𝑑𝑑𝑑𝑑𝑤𝑤𝑤𝑤1 is the operating pitch diameter of the pinion.
analysis due to the need of using a large number of finite elements
under the surface in the finite element mesh. Those finite element
The contact point in which the contact stress number is determined i
meshes would be extremely costly for computation. Instead, the The contact point in which the contact stress number is deter-
maximum value of contact pressure has been found not being so factor is𝑍𝑍𝑍𝑍𝐼𝐼𝐼𝐼considered
mined . For spurthrough
and low axial
the contact
geometry ratio
factor helical
ZI. For gears,
spur and low the geom
sensitive to the finite element mesh used for computations, and it is considering the radius of curvature of pinion and gear
axial contact ratio helical gears, the geometry factor ZI is calculated for contact at
recommended as the main indicator of contact stresses for compari- contact (LPSTC)
considering for of
the radius thecurvature
pinion. For conventional
of pinion and gear helical gears, the g
for contact
son between different gear designs. Besides, either the AGMA or ISO considering
at the lowest point the radii of curvature
of single of pinion
tooth contact andfor
(LPSTC) gear
the for contact at th
pinion.
methodologies use contact pressure (Hertz pressure) as the basis for For conventional
working helical
profile of gears, the
the pinion geometry factor ZI is calculated
[10].
their calculations (see Section 3). considering the radii of curvature of pinion and gear for contact
Regarding bending stresses, Von Mises stresses may be affected at the mean radius or middle radius of the working profile of the
The effective allowable stress number 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃eff is obtained as a functio
by some contact positions where the load is shared between two pinion [10].
pairs of teeth and the traction due to the bending of a given tooth is number of the material,
The effective allowable 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃 , modified
number sHPeff isby the stress
obtained cycle factor for p
as a function
low in comparison with the compression in the same fillet area due ratio
of thefor pitting contact
allowable resistance, 𝑊𝑊𝑊𝑊 , the temperature
stress𝑍𝑍𝑍𝑍number of the material, factor, 𝑌𝑌𝑌𝑌𝜃𝜃𝜃𝜃 , and the re
sHP, modi-
to the bending of the previous tooth. Also, contacts near the form effective
fied by theallowable
stress cyclestress number
factor for is:
pitting𝜎𝜎𝜎𝜎resistance,
𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃
ZN , the hardness
eff

32     gearsolutions.com
𝑍𝑍𝑍𝑍𝑁𝑁𝑁𝑁 𝑍𝑍𝑍𝑍𝑊𝑊𝑊𝑊
𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 = 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃
𝑌𝑌𝑌𝑌 𝑌𝑌𝑌𝑌𝑍𝑍𝑍𝑍
The effective allowable stress number 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃eff is obtained as a function of the allowable contact stress
number
ration forof the material,
pitting ZW,, the
resistance,𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃 modified
temperature by thefactor,
stressY cycle factor for pitting resistance, 𝑍𝑍𝑍𝑍𝑁𝑁𝑁𝑁 , the hardness
q, and the
ratio for pitting
reliability factor,resistance,
YZ. The formula 𝑍𝑍𝑍𝑍𝑊𝑊𝑊𝑊 , for
thethe
temperature factor, stress
effective allowable 𝑌𝑌𝑌𝑌𝜃𝜃𝜃𝜃 , and the reliability factor, 𝑌𝑌𝑌𝑌𝑍𝑍𝑍𝑍 . The formula for the
effectivesHP
number allowable
eff
is: stress number 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃eff is:

𝑍𝑍𝑍𝑍𝑁𝑁𝑁𝑁 𝑍𝑍𝑍𝑍𝑊𝑊𝑊𝑊
𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 = 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃 (2)
𝑌𝑌𝑌𝑌𝜃𝜃𝜃𝜃 𝑌𝑌𝑌𝑌𝑍𝑍𝑍𝑍

The The bendingresistance

bending resistance isisbased
based on aon
model that considers
a model a canti- a cantilever plate and the tensile stresses
that considers
The bending
lever resistance
plate and the is based
tensile stresses on aon
obtained model that
the side considers a cantilever plate and the tensile stresses
of application
obtained on the side of application of the load. When we extrapolate it to gears, the bending model gives
obtained
of the load.on thewe
When side of application
extrapolate of the
it to gears, the load.
bendingWhen
modelwe extrapolate it to gears, the bending model gives
gives
thetensile
tensilestress
stress in the fillet area of the driving side of teeth.
the gear teeth. The bending stress number 𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹 in a
the tensile stress in the fillet area of the driving side of the gear teeth. The bending stress number 𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹 in a
the in the fillet area of the driving side of the gear
gearbending
The tooth is given by: sF in a gear tooth is given by:
gear tooth isstress
givennumber
by: 4 17FTM03
1 𝐾𝐾𝐾𝐾 𝐾𝐾𝐾𝐾
𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹 = 𝐹𝐹𝐹𝐹𝑡𝑡𝑡𝑡 𝐾𝐾𝐾𝐾𝑜𝑜𝑜𝑜 𝐾𝐾𝐾𝐾𝑣𝑣𝑣𝑣 𝐾𝐾𝐾𝐾𝑠𝑠𝑠𝑠 1 𝐾𝐾𝐾𝐾𝐻𝐻𝐻𝐻 𝐾𝐾𝐾𝐾
𝐵𝐵𝐵𝐵
(3)
𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹 = 𝐹𝐹𝐹𝐹𝑡𝑡𝑡𝑡 𝐾𝐾𝐾𝐾𝑜𝑜𝑜𝑜 𝐾𝐾𝐾𝐾𝑣𝑣𝑣𝑣 𝐾𝐾𝐾𝐾𝑠𝑠𝑠𝑠 𝑏𝑏𝑏𝑏 𝑚𝑚𝑚𝑚𝑡𝑡𝑡𝑡 𝐻𝐻𝐻𝐻𝑌𝑌𝑌𝑌𝐽𝐽𝐽𝐽 𝐵𝐵𝐵𝐵 (3)
𝑏𝑏𝑏𝑏 𝑚𝑚𝑚𝑚𝑡𝑡𝑡𝑡 𝑌𝑌𝑌𝑌𝐽𝐽𝐽𝐽

where
where
𝐾𝐾𝐾𝐾𝐵𝐵𝐵𝐵 is the rim thickness factor,
𝐾𝐾𝐾𝐾𝐵𝐵𝐵𝐵 is the rim thickness factor,
𝑌𝑌𝑌𝑌𝐽𝐽𝐽𝐽 is the geometry factor for bending strength, and
𝑌𝑌𝑌𝑌𝐽𝐽𝐽𝐽 is the geometry factor for bending strength, and
𝑚𝑚𝑚𝑚𝑡𝑡𝑡𝑡 is the transverse metric module in millimeters.
𝑚𝑚𝑚𝑚𝑡𝑡𝑡𝑡 is the transverse metric module in millimeters.
The The effectiveallowable
effective allowable bending bendingstress stress number
number,sHPeff 𝜎𝜎𝜎𝜎, depends on
, depends on the allowable bending stress number
Theallowable
the effectivebending
allowable bending
stress numberstress number,s𝜎𝜎𝜎𝜎HP𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃
of the material
eff , depends on the allowable bending stress number
, modified
𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃
  eff
of the material, 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃 , modified by the stress cycle factor for bending strength, 𝑌𝑌𝑌𝑌𝑁𝑁𝑁𝑁 , the temperature factor,
of the
by the stress
material, 𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃 , modified
cycle𝜎𝜎𝜎𝜎factor for bending by the stressYNcycle
strength, factor for bending strength, 𝑌𝑌𝑌𝑌𝑁𝑁𝑁𝑁 , the temperature factor,
, the temperature
𝜃𝜃𝜃𝜃 , and
𝑌𝑌𝑌𝑌
factor, Y the
, andreliability
the reliability factor,
factor, 𝑌𝑌𝑌𝑌𝑍𝑍𝑍𝑍 , Ysimilar
, to to
similar thethecase
caseof of contact
contact stress. The formula to calculate the effective
𝑌𝑌𝑌𝑌𝜃𝜃𝜃𝜃 , andqthe reliability factor, 𝑌𝑌𝑌𝑌𝑍𝑍𝑍𝑍 , similar Z to the case of contact stress. The formula to calculate the effective
allowable
stress. stress to
The formula number calculate𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃
the is
eff effective allowable stress number
allowable stress number 𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃 eff
is
sHPeff is:
𝑌𝑌𝑌𝑌
𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 = 𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃 𝑌𝑌𝑌𝑌𝑁𝑁𝑁𝑁 (4)
𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 = 𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃 𝑌𝑌𝑌𝑌𝜃𝜃𝜃𝜃𝑁𝑁𝑁𝑁𝑌𝑌𝑌𝑌𝑍𝑍𝑍𝑍 Figure 1 – Finite element model
Figure 1: Finite withmodel
element fivewith
pairs
five of teeth
pairs having
of teeth (4) aauniform
having uniformlayerlayer
of of fini
𝑌𝑌𝑌𝑌𝜃𝜃𝜃𝜃 𝑌𝑌𝑌𝑌𝑍𝑍𝑍𝑍
finite element conforming
conforming thethe contacting surfaces
contacting surfacesof the of
gears.
the gears.

4 FINITE
4: Finite element
ELEMENT analysis
ANALYSIS 5: COMPARISON OF THE MECHANICAL BEHAVIOR
4 Finite element analysis A model as the one shown in Figure 1 has been considered for the analysis. Sixty-one conta
Before the application of finite element analysis, tooth contact analy- OF CYLINDRICAL SPUR GEARS WITH HIGH
Before the application of finite element analysis, distributed tooth contact
along analysis
two cycles (TCA) has
of meshing aretoinvestigated
be performed to
to capture every detail of the evoluti
Before
sis (TCA)the
has application
to be performed of finite element
to obtain analysis,
the angular tooth of
positions contact
pin- PRESSURE
analysis (TCA)ANGLEShas to be performed to
obtain
ion the
and the angular
gearangular
along one positions of
or two cycles pinion and
of meshing. gear
and along
bending one
A general-purpose or
stresses twoallcycles
over twoof meshing.
cycles
Three cylindrical of A general-purpose
meshing.
gear sets with different pressure angles are
obtain positions of pinion and gear along one or two cycles of meshing. A general-purpose
algorithm for
algorithm for simulation of meshing
meshingand andcontact
contactofofpinionpinionand and gear toothandsurfaces is used. This algorithm
algorithm for simulation of meshing and contact of pinion and gear tooth surfaces is used. Thiscontact
simulation of analyzed compared regarding and bending stresses, as
algorithm
is based
gear toothon a numerical
surfaces method
is used. This that takes
algorithm is basedintoonaccount
a numericalthe position
well asofthe the toothfunction
loaded surfaces of and minimizes
transmission errors. Figure 2 shows
is based on a numerical method that takes5 into account Comparison of theofmechanical
the position the tooth surfacesbehavior andof cylindrical spur gears with hig
minimizes
the distance
method untilinto
that takes contact
account is the
achieved
position[11].
of theThe
tooth algorithm
surfaces and assumes rigidtooth
the gear bodygeometry
behavior of and has beengear sets. Table 1 provides
the evaluated
the distance
minimizes until
thetwo
distancecontact
until is achieved [11]. The pressure
algorithm angles
assumes rigid body behavior and ofhas been
extended to cycles of contact
meshing is achieved
in [12]. It [11].
is The
valid algorithm the general
for linear, point, or edge design parameters
contacts. A grid the
of 61evaluated
× 61 spur gear sets. For
extended
assumes to two
rigid bodycycles
behavior ofand
meshing
has been in extended
[12]. It istovalid
two for linear,
cycles of point,
all or the
cases, edge contacts.
center distance Aand
gridnumber
of 61 ×of61teeth of pinion and gear regard
points on each gear tooth surface, a total of Three
three cylindrical
pairs of gear
toothsets with different
surfaces, and a pressure angles are analyzed
virtual compound and compared
points onineach
meshing [12]. Itgear tooth
is valid for surface, a total
linear, point, of
or edge three pairs
contacts.
and bending A of
gridtooth
stresses, surfaces,
are kept
as well as and
constant. a virtual
The
the loaded compound
addendum
function and dedendum
of transmission coefficients of the
errors. Figure 2 shows t
thickness of 0.0065
61 × 61 points
mmgear have been considered here for determination of contact patterns and functions
thickness
of of 0.0065
on eachmm have been
tooth considered
surface, a total of
tooth here
three
geometry for determination
pairs
of the
generating
evaluated of contact
rack cutters
gear sets. patterns and
are adjusted
Table 1 functions
provides
to avoid pointing of the gear
the general design parameters o
of tooth
of unloaded transmission
surfaces, and a virtual errors.
compound thickness of 0.0065 mm teeth for all cases. The root radius coefficient is also chosen to allow
of unloaded transmission errors. evaluated spur gear sets. For all cases, the center distance and number of teeth of pinion an
have been considered here for determination of contact patterns and for a suitable geometry of the generating tool. The profile shift coef-
Finite element models are built automatically keptfromconstant. The tooth
the gear addendum
surfacesand and
dedendum
following coefficients of thethat
generating rack cutters are a
functions of unloaded transmission errors. ficients for each gear set wereaselected
procedure for optimal specific sliding.
Finite element models are built automatically avoid from the
pointing gear tooth
of the gearThesurfaces
teeth and following a procedure that
is extensively
Finite element illustrated
models areinbuilt [13]. Node coordinates
automatically from the are
geardetermined
tooth theforgear
on most all cases.derived
tooth The
important root
surfaces radius coefficient
as a function
parameters is alsogear
of the evaluated chosen
sets to allo
is extensively
surfaces and illustrated
following a in [13]. that
procedure Node is coordinates
suitable
extensively are determined
geometry
illustrated in of the
are on thein
generating
shown gear
Table tooth
tool. The
2. surfaces
Theprofile
transverseascoefficients
shift a function
contact for
ratio each gear
decreases as set were
the
of the chosen numbers of nodes in longitudinal, profile, and fillet directions. The finite element model
of the
[13]. chosen
Node numbers
coordinates of nodes inonlongitudinal,
are determined optimal
the gear toothprofile,
specific
surfacesandas fillet
sliding. directions.
pressure angle The finite as
increases, element
shown in model
Table 2.
considers five pairs of teeth to keep the boundary conditions, represented by a rigid surface, far enough
aconsiders
function offive
thepairs
chosenof numbers
teeth to of
keep theinboundary
nodes conditions,
longitudinal, profile, represented
The ratingby a rigid
of the surface,
three far enough
designs presented in Table 1 is performed
from the contact areas. A reference node on the axis of the pinion (respectively, the gear) controls the
fromfillet
and thedirections.
contact areas. A reference
The finite nodeconsiders
element model on the axis of the
five pairs of pinion (respectively,
according to the AGMAthe gear) controls
2101-D04 the A torque of 900 Nm is
standard.
bodyto motion ofboundary
the rigid surface. Whereas the
byrigid
a rigidsurface
surface,of the geartoisthe
applied held at rest
pinion at gear
of the each contact
teeth keep the
body motion of the rigidconditions, represented
surface. Whereas the rigid surface of the gear is held at rest at eachset. A speed of 1 rpm is considered
contact
position by blocking its reference node, a torque about the pinion axis is applied to the reference node of
position by blocking its reference node, a torque about the pinion axis is applied to the referencegear
far enough from the contact areas. A reference node on the axis of the to neglect the dynamic effects on the nodeperformance.
of Most of the
the pinion
pinion rigid surface.
(respectively, the gear) controls the body motion of the rigid factors of influence on the contact and bending stress numbers have
the pinion rigid surface.
surface. Whereas the rigid surface of the gear is held at rest at each been taken into account equal to 1.0, to isolate the effect of the geom-
contact position by blocking its reference node, a torque about the etry on the stresses (see Table 3). The stress cycle factor for all cases of
pinion axis is applied to the reference node of the pinion rigid surface. design corresponds to a service life6 of 20,000 hours.
A model as the one shown in Figure 1 has been considered for the Table 3 shows the factors of influence and main parameters
analysis. Sixty-one contact positions distributed along two cycles of affecting the calculation of the contact and bending stress numbers
meshing are investigated to capture every detail of the evolution of according to AGMA 2101-D04. Steel, grade 2, carburized and
contact and bending stresses all over two cycles of meshing. hardened, having an allowable contact stress number of 1,550 MPa
June 2018     33
 Table 1 – General design parameters of spur gear sets.

GEAR SET 1 GEAR SET 2 GEAR SET 3

(PA25) (PA30) (PA35)
PARAMETER PINION GEAR PINION GEAR PINION GEAR
Number of teeth, 𝑁𝑁𝑁𝑁 16 29 16 29 16 29
Module, 𝑚𝑚𝑚𝑚 [mm] 4.0 4.0 4.0
Table 2 – Derived geometric parameters of evaluated spur gear sets.
Helix angle, 𝛽𝛽𝛽𝛽 [deg.] 0.0 0.0 0.0
Center distance, 𝐶𝐶𝐶𝐶 [mm] GEAR SET 1
90.0 GEAR
90.0 SET 2 GEAR
90.0SET 3
(PA35)
Pressure angle, 𝛼𝛼𝛼𝛼 [deg.] 25.0 (PA25) (PA30)
30.0 35.0
PARAMETER
Profile shift coefficient, 𝑥𝑥𝑥𝑥 0.1845PINION
−0.1845GEAR 0.1229
PINION −0.1229
GEAR PINION −0.0757
0.0757 GEAR
Transverse contact ratio
Addendum coefficient, ℎ𝑎𝑎𝑎𝑎 1.00 1.403
1.00 0.95 1.248
0.95 0.85 1.072 0.85
Operating
Dedendumpitch diameter,
coefficient, ℎ𝑓𝑓𝑓𝑓 𝑑𝑑𝑑𝑑𝑤𝑤𝑤𝑤 [mm]
1.25 64 1.25 116 1.15 64 1.15116 64
1.05 116
1.05
Root diameter [mm]
Root radius coefficient, 𝜌𝜌𝜌𝜌𝑓𝑓𝑓𝑓 0.317 55.4760.317
104.524 0.21
55.784 105.816
0.21 55.806
0.09 106.594
0.09
Specific sliding at the tip [mm] 0.621 0.621 0.492 0.492 0.377 0.377
Face width, 𝑏𝑏𝑏𝑏 [mm] 50.0 50.0 50.0 50.0 50.0 50.0
Specific sliding at the root [mm] −1.641 −1.641 −0.969 −0.969 −0.605 −0.605
TheBase
Table 1:pitch
most [mm]
important
General derived
design parameters
parameters the 11.389
of spurofgear evaluated
sets. gear sets are10.883
shown in Table 2. The10.294
transverse
Table 2as
contact ratio decreases – Derived geometric
the pressure parameters
angle increases, asof evaluated
shown spur
in Table 2. gear sets.
The rating of the three designs presented in Table 1 is performed according to the AGMA 2101-D04
GEAR SET 1 GEAR SET 2 GEAR SET 3
standard. A torque of 900 Nm is applied to the pinion of the gear set. A speed of 1 rpm is considered to
(PA25) (PA30) (PA35)
neglect the dynamic effects on the gear performance. Most of the factors of influence on the contact and
PARAMETER PINION
bending stress numbers have been taken into account GEAR PINION GEAR PINION GEAR
7 equal to 1.0, to isolate the effect of the geometry
17FTM03
onTransverse
the stressescontact
(see Table
ratio 3). The stress cycle1.403 factor for all cases of design
1.248 corresponds to 1.072
a service life
of Operating
20,000 hours.
pitch diameter, 𝑑𝑑𝑑𝑑𝑤𝑤𝑤𝑤 [mm] 64 116 64 116 64 116
Root diameter [mm] 55.476 104.524 55.784 105.816 55.806 106.594
Table 3 shows the factors of influence and main parameters affecting the calculation of the contact and
bending stress numbers according to AGMA 2101-D04. Steel, grade 2, carburized and hardened,0.377
Specific sliding at the tip [mm] 0.621 0.621 0.492 0.492 0.377 having
anSpecific sliding
allowable at the
contact rootnumber
stress [mm] of 1550−1.641
MPa and −1.641 −0.969
an allowable bending−0.969 −0.605
stress number −0.605
of 450.0 MPa
was
ure 2 – Gear tooth geometry of the evaluated spur gear Base pitch [mm]
selected
sets. 11.389
for the calculations of the safety factors. 10.883 10.294
Figure 2: Gear tooth geometry of the evaluated spur
Table
gear sets. Table 1 – General design parameters of
The 2: Derived
Table
rating 3of–the geometric
Factors
three of parameters
influence
designs presented onofthe
evaluated
Table spur
incalculation gear
of thesets.
1 is performed contact and bending
according stress
to the AGMA numbers
2101-D04
spur gear sets. standard. A torque of 900 Nm is applied according to AGMA
to the pinion of the2101-D04.
gear set. A speed of 1 rpm is considered to
neglect the dynamic effects on the gear performance. Most of the factors of influence on the contact and
Table 1 – General design parameters of spur gear sets. GEAR SET 1 GEAR SET 2 GEAR SET 3
and an allowable bending stress number of bending stress numbers have been taken into account equal to 1.0, to isolate the effect of the geometry
(PA25) (PA30) (PA35)
onPARAMETER
the stresses
GEAR SET 3 (see Table 3). The stress cycle factor for all cases of design corresponds to a service life
GEAR
450.0 MPa SET
was 1
selected for theGEAR SET 2
calculations Nominal circumferential force, 𝐹𝐹𝐹𝐹 [N] 28125.00 28125.00 28125.00
of 20,000 hours.
(PA35) 𝑡𝑡𝑡𝑡
(PA25)
of the safety factors.] (PA30)
Radial force, 𝐹𝐹𝐹𝐹𝑟𝑟𝑟𝑟 [N] 13114.90 16238.00 19693.30
Table 4 shows
PINION GEAR the safety
PINIONfactorsGEAR
for TablePINION
3 shows the GEARfactors of influence and main parameters affecting the calculation of the contact
Geometry factor, 𝑍𝑍𝑍𝑍𝐼𝐼𝐼𝐼 0.112 0.122 0.130 and
pitting
16 and bending
29 according 16 to AGMA 29 bending 16stress numbers 29 according to AGMA 2101-D04. Steel, grade 2, carburized and hardened, having
Elastic coefficient, 𝑍𝑍𝑍𝑍 𝐸𝐸𝐸𝐸 [N/mm 2]0.5 190.20 190.20 190.20
2101-D04 for the three designs of spur gear an allowable contact stress number of 1550 MPa and an allowable bending stress number of 450.0 MPa
4.0 4.0 wasOverload
selected
4.0the𝐾𝐾𝐾𝐾𝑜𝑜𝑜𝑜calculations of the safety factors.
factor,
for 1.0 1.0 1.0
sets. According to the standard, the pressure
0.0 0.0 Load 0.0
distribution factor, 𝐾𝐾𝐾𝐾𝐻𝐻𝐻𝐻 1.0 1.0 1.0
angle improves both the safety factor for
mm] 90.0 90.0 in Table
Dynamic 3 – Factors
factor,
90.0 𝑣𝑣𝑣𝑣𝐾𝐾𝐾𝐾 of influence on the calculation
1.0 of the contact and
1.0 bending stress numbers
1.0
pitting and that for bending. As shown according to AGMA 2101-D04.
eg.] 25.0 Size factor, 𝐾𝐾𝐾𝐾
30.0 for a 35.0 1.0 1.0 1.0
Table 4, the maximum contact stress 𝑠𝑠𝑠𝑠

nt, 𝑥𝑥𝑥𝑥 spur0.1845

gear drive−0.1845 −0.1229 Temperature
0.1229 pressure
with 30-degree 0.0757 factor, −0.0757 𝑌𝑌𝑌𝑌𝜃𝜃𝜃𝜃 GEAR 1.0SET 1 GEAR 1.0SET 2 GEAR 1.0SET 3
Reliability
PARAMETER factor, 𝑌𝑌𝑌𝑌𝑍𝑍𝑍𝑍 (PA25)
1.0 (PA30)
1.0 (PA35)
1.0
nt, ℎ𝑎𝑎𝑎𝑎 angle is
1.00 reduced 4.38
1.00 percent with
0.95 respect
0.95 0.85 0.85
to a similar design having a pressure angle Surface
Nominal condition
circumferential factor,force, 𝑍𝑍𝑍𝑍𝑅𝑅𝑅𝑅 𝐹𝐹𝐹𝐹𝑡𝑡𝑡𝑡 [N] 1.0
28125.00 1.0
28125.00 1.0
28125.00
nt, ℎ𝑓𝑓𝑓𝑓 1.25 1.25 1.15 1.15 the design1.05 having the 1.05 pressure angle of 25 . The corresponding bending stresses are reduced by 25.6%
o

of 25 degrees. Bending stresses are also forHardness Radial force, ratio 𝐹𝐹𝐹𝐹𝑟𝑟𝑟𝑟 factor,
[N] 𝑍𝑍𝑍𝑍𝑊𝑊𝑊𝑊
the design having a pressure angle of 35 . Generally speaking, and based on the results obtained, by o 1.0
13114.90 1.0
16238.00 1.0
19693.30
nt, 𝜌𝜌𝜌𝜌𝑓𝑓𝑓𝑓 0.317 0.317 0.21 0.21 Stress
0.09cycle factors,
0.09 − 𝑌𝑌𝑌𝑌 1.126 − 1.16 − 1.16factor for pitting −and
reduced 12.4 percent for the design having increasing Geometry thefactor,
pressure 𝑍𝑍𝑍𝑍𝐼𝐼𝐼𝐼 𝑍𝑍𝑍𝑍𝑁𝑁𝑁𝑁angle 𝑁𝑁𝑁𝑁 as much as geometrically 0.112 is possible,1.126the0.122
safety 1.1260.130 1.16
50.0
a pressure 50.0
angle 50.0
of 30 degrees. For 50.0
the bending 50.0
Elastic coefficient,
is improved, 50.0 𝐸𝐸𝐸𝐸 [N/mm
𝑍𝑍𝑍𝑍so that the 2]0.5
transmissible power 190.20 can be increased190.20 accordingly. 190.20
Table 3:
Table Factorsthe
4 shows of influence
safety factors on theforcalculation
pitting and ofbendingthe contact and bending
according stress2101-D04
to AGMA numbers according
for the threeto AGMA
design with the higher-pressure angle (35 Overload factor, 𝐾𝐾𝐾𝐾𝑜𝑜𝑜𝑜 1.0 1.0 1.0
rived parameters 2101-D04.
designs of spur gear sets. According to the standard, the pressure angle improves both the safety factor
degrees), of thecontact
the evaluated gear sets
stresses are are shown in Table
reduced 2. The transverse
Load distribution
Table 4factor, – Safety 𝐾𝐾𝐾𝐾𝐻𝐻𝐻𝐻 factors for pitting and 1.0bending according 1.0to AGMA 2101-D04. 1.0
s as the pressure angle increases, as shown in Table 2. for pitting and that for bending. As shown in Table 4, the maximum contact stress for a spur gear drive
by 7.30 percent with respect to the design with Dynamic factor,angle
30o pressure 𝐾𝐾𝐾𝐾𝑣𝑣𝑣𝑣 is reduced a 4.38% with respect 1.0 to a similar design 1.0 having a pressure1.0 angle of
having the pressure angle of 25 degrees. The 25Size GEAR SET 1 GEAR SET 2 GEAR SET 3
factor,stresses
o. Bending 𝐾𝐾𝐾𝐾𝑠𝑠𝑠𝑠 are also reduced a 12.4% for1.0 the design having a 1.0 pressure angle of 30o1.0 . For the
PARAMETER (PA25) (PA30) (PA35)
corresponding bending stresses are reduced design with the higher
Temperature factor, pressure 𝑌𝑌𝑌𝑌𝜃𝜃𝜃𝜃 angle (35o), the contact 1.0 stresses are reduced 1.0 by a 7.30% with1.0 respect to
by 25.6 percent for the design having a Contact stress number,
Reliability factor, 𝑌𝑌𝑌𝑌𝑍𝑍𝑍𝑍 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻 [N/mm 2]
1.0 1684.89 1.0 1611.05 1561.97
1.0
7 17FTM03
pressure angle of 35 degrees. Generally Allowable contact stress
Surface condition factor,number, 𝑍𝑍𝑍𝑍𝑅𝑅𝑅𝑅 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃 [N/mm2] 1.0 8 1550.00 1.0 1550.00 1550.00
1.0 17FTM03
speaking, and based on the results obtained, Effective allowable
Hardness ratio factor, 𝑍𝑍𝑍𝑍𝑊𝑊𝑊𝑊 contact stress number, 𝜎𝜎𝜎𝜎 [N/mm
𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃eff 1.0
2]
1745.30 1.0 1745.30 1745.30
1.0
by increasing the pressure angle as much as Stressfactor factors, 𝑍𝑍𝑍𝑍𝑆𝑆𝑆𝑆𝑁𝑁𝑁𝑁𝐻𝐻𝐻𝐻 − 𝑌𝑌𝑌𝑌𝑁𝑁𝑁𝑁
cycle (pitting), 1.126 − 1.16 1.126 − 1.16 1.08 1.126 −1.12 1.16
Safety 1.036
geometrically is possible, the safety factor
Bending stress number, 𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹 [N/mm2] 320.36 280.71 238.28
for pitting and bending is improved, so that Table 4 shows the safety factors for pitting and bending according to AGMA 2101-D04 for the three
the transmissible power can be increased designs Allowableof spurbending gear stress sets. According number, 𝜎𝜎𝜎𝜎to [N/mm
𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃 the standard,
2]
the pressure 450.00
angle improves 450.00
both the safety450.00
factor
accordingly. forEffective
pitting and that forbending
allowable bending.stress As shownnumber, in Table
𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃eff4,[N/mm
the maximum
2] contact stress
522.00 for a spur gear
522.00 drive
522.00
Regarding the results obtained from with 30o pressure angle is reduced a 4.38% with respect to a similar design having a pressure angle of
Safety factor (bending), 𝑆𝑆𝑆𝑆𝐹𝐹𝐹𝐹 1.63 1.86 2.19
25o. Bending stresses are also reduced a 12.4% for the design having a pressure angle of 30o. For the
the application of the finite element
design with the higher pressure angle (35o), the contact stresses are reduced by a 7.30% with respect to
Table 4: Safety
method, Figure 3 shows the evolution of the Regarding factors obtained
the results for pittingfrom and bending
the application according of to
theAGMA
finite2101-D04.
element method, Figure 3 shows the
evolution of the maximum contact pressure along sixty-one contact positions distributed in two cycles of
34     gearsolutions.com 8
meshing. The contact pressure is obtained at the middle tooth of a total of five teeth of the pinion17FTM03
model. It
is observed, for each case of design, that the maximum contact pressure occurred, certainly, at the
 with 35o as AGMA 2104-D04 predicts. The reduction of the transverse contact ratio bending stress
for high with respect to the previous case. Therefore, the idea that higher pressure angles wil
pressure
reduce
angle gears is also noted on the shorter portion along the sixty-one contact positions bending
for which stresses cannot be generalized. One of the main influences on the bending stresses
a gear
tooth is in contact under pressure (see Figure 3). the evaluated cases is the different values of the root radius coefficient used for each design.

hows the evolution of maximum Von Mises stress on the contacting surfaces of the pinion
highest value of Von Mises stress occurs underneath the contacting surfaces, as Hertz theory
Considering the applied finite element model as a reference for comparison without further
e accuracy of the obtained results (since a higher amount of finite elements would be required
etter estimation of the real Von Mises stresses), Figure 4 shows the same tendency on the
of the maximum Von Mises stresses on the contacting surfaces of the pinion, experiencing the
lue at the LPSTC. A slight reduction of the contact stresses is also observed for the design with
ssure angles, and it is in agreement with the results obtained for the contact pressure and
by the analytical method.
shows the evolution of maximum Von Mises stress on the contacting surfaces of the pinion
e highest value of Von Mises stress occurs underneath the contacting surfaces,Figure as Hertz 6 –theory
Evolution of maximum principal stress (larger tension)
Considering the applied finite element model as a reference for comparison without further at the fillet area of the gear teeth.
he accuracy of the obtained results (since a higher amount of finite elements would be required
etter estimation of the real Von Mises stresses), Figure 4 shows the same tendency on the
of the maximum Von Mises stresses on the contacting surfaces Figure
of the7 pinion,
shows the loaded function
experiencing the of transmission errors for the three cases of design evaluated i
alue at the LPSTC. A slight reduction of the contact stresses iswork.
also The maximum
observed for peak-to-peak
the design withvalue of transmission errors is decreasing when the pressure an
Figure 3 – Evolution of the maximum contact pressure onincreases.
the surfacesThe Discrete Fourier Transform
Figure 3: Evolution of the
essure angles, and it is in agreement maximum contact
of the middlewith
pairthe
pressure on the
results obtained
of contacting teeth.
surfaces of the middle
for the contact pressureFigure
Figure and
6: 6Evolution
– Evolution of(DFT)
maximum
of maximum
of these functions
principalprincipal
should
stress
stress (larger
be tension)
(larger
tension)
evaluated before dra
at the fillet area
pair of contacting teeth. final conclusions in terms of noise and vibration excitation.
by the analytical method. of the gear teeth. at the fillet area of the gear teeth.

Figure 7 shows the loaded function of transmission errors for the three cases of design evaluated in
9 17FTM03
work. The maximum peak-to-peak value of transmission errors is decreasing when the pressure ang
increases. The Discrete Fourier Transform (DFT) of these functions should be evaluated before draw
final conclusions in terms of noise and vibration excitation.

– Evolution of the maximum Von Mises stress on the contacting surfaces of the pinion.

bending stresses, Figure 5 shows the evolution of the maximum principal stress at the pinion
g sixty-one contact positions. The maximum value occurs at the highest point of single tooth
PSTC), as AGMA predicts. However, the results of maximum stresses and relative comparison
nt from those obtained through the application of the analytical model. In fact, an increment of
um principal stress is observed as the pressure angle increases. It is clearly seen in Figure 5
ortion of meshing for single tooth contact is increased as the pressure angle increases.
he–maximum
4 Evolutionbending stress is well
of the maximum Vonpredicted by the on
Mises stress analytical model forsurfaces
the contacting the pressure
of theangle of
pinion.
Figure 4: Evolution of the maximum Von Mises stress on the contacting surfaces
predicts that the bending stresses should be decreasing, but on the contrary, in Figure Figure 5, it is function of transmission errors for spur gears with different
7: Loaded
of the pinion. Figure 7 – Loaded function of transmission errors for spur gears with different pressure an
hat the maximum principal stress is increasing for the pinion as the pressure anglepressure angles.
increases.
g bending stresses, Figure 5 shows the evolution of the maximum principal stress at the pinion
ng sixty-one contact positions. The maximum value occurs at the highest point of single tooth
HPSTC), as AGMA predicts. However, the results of maximum stresses and relative comparison
Figure 4 shows the evolution of maximum Von Mises stress on
ent from those obtained through the application of the analytical model. In fact, an increment the contacting of surfaces of the pinion teeth. The highest value of Von
Figure 7 – Loaded function 11 for spur gears with different pressure ang
of transmission errors 17
mum principal stress is observed as the pressure angle increases. It is clearly seen in Figure 5occurs underneath the contacting surfaces, as Hertz
Mises stress
portion of meshing for single tooth contact is increased as the pressure angle increases. theory predicts. Considering the applied finite element model as
the maximum bending stress is well predicted by the analytical model for the pressure a reference
angle for of comparison without further judging the accuracy
o predicts that the bending stresses should be decreasing, but on the contrary, inof the obtained
Figure 5, it is results (since a higher amount of finite elements
11 estimation of the real Von Mises 17F
that the maximum principal stress is increasing for the pinion as the pressure angle wouldincreases.
be required to get a better
stresses), Figure 4 shows the same tendency on the evolution of the
maximum Von Mises stresses on the contacting surfaces of the pin-
ion, experiencing the highest value at the LPSTC. A slight reduction
of the contact stresses is also observed for the design with higher
pressure angles, and it is in agreement with the results obtained for
the contact pressure and predicted by the analytical method.
Regarding bending stresses, Figure 5 shows the evolution of the
Figure
Figure55:–Evolution
Evolution of maximum
of maximum principal principal stress
stress (larger (larger
tension) tension)
at the fillet area maximum principal stress at the pinion fillet during 61 contact
at the fillet area of the pinion teeth.
of the pinion teeth. positions. The maximum value occurs at the highest point of single
tooth contact (HPSTC), as AGMA predicts. However, the results of
maximum contact pressure along 61 contact positions distributed in maximum stresses and relative comparison are different from those
10 17FTM03
two cycles of meshing. The contact pressure is obtained at the middle obtained through the application of the analytical model. In fact,
tooth of a total of five teeth of the pinion model. It is observed, for an increment of the maximum principal stress is observed as the
each case of design, that the maximum contact pressure occurred, pressure angle increases. It is clearly seen in Figure 5 how the portion
certainly, at the LPSTC point. A minor reduction of contact pressure of meshing for single tooth contact is increased as the pressure angle
is observed from the design with 25 degrees to the design with 35
Figure 5 – Evolution of maximum principal stress (larger tension) increases. Although the maximum bending stress is well predicted
degrees as AGMA at 2104-D04
the fillet area of the
predicts. Thepinion teeth.
reduction of the transverse by the analytical model for the pressure angle of 25 degrees, it also
contact ratio for high pressure angle gears is also noted on the shorter predicts that the bending stresses should be decreasing, but on the
portion along the sixty-one contact positions for which a gear tooth contrary, in Figure 5, it is observed that the maximum principal
is in contact under pressure (see 10 Figure 3). 17FTM03
stress is increasing for the pinion as the pressure angle increases.
June 2018     35
 the previously analyzed designs of spur gear sets. A helix angle of 20 degrees was chosen for all
Table 5 – General design parameters of helical gear sets.
designs.
GEAR SET 1 GEAR SET 2 GEAR SET 3
Table 5 – General design parameters of helical gear sets. (PA35)
(PA25) (PA30)
Figure 6 shows the evolution of the GEAR SET 3
PARAMETER GEAR
PINION SET 1
GEAR GEAR
PINION SET 2
GEAR PINION GEAR
maximum principal stress at the fillet area (PA25) (PA30) (PA35)
of the middle tooth of the gear for the three Number of teeth, 𝑁𝑁𝑁𝑁 16 29 16 29 16 29
PARAMETER PINION GEAR PINION GEAR PINION GEAR
cases of design. Although some reduction Module, 𝑚𝑚𝑚𝑚 [mm] 4.0 4.0 4.0
of bending stresses is obtained for the Number of teeth, 𝑁𝑁𝑁𝑁 16 29 16 29 16 29
Helix angle, 𝛽𝛽𝛽𝛽 [deg.] 20.0 20.0 20.0
design with 30 degrees at the fillets of the Module, 𝑚𝑚𝑚𝑚 [mm] 4.0 4.0 4.0
Hand of helix Right Left Right Left Right Left
gear teeth, design with 35 degrees shows Helix angle, 𝛽𝛽𝛽𝛽 [deg.] 20.0 20.0 20.0
Center distance, 𝐶𝐶𝐶𝐶 [mm] 95.776 95.776 95.776
an increment on the maximum bending Hand of helix Right Left Right Left Right Left
Pressure angle, 𝛼𝛼𝛼𝛼 [deg.] 25.0 30.0 35.0
stress with respect to the previous case. Center distance, 𝐶𝐶𝐶𝐶 [mm] 95.776 95.776 95.776
Therefore, the idea that higher pressure Profile shift coefficient, 𝑥𝑥𝑥𝑥 0.1599 −0.1599 0.1064 −0.1064 0.0657 −0.0657
Pressure angle, 𝛼𝛼𝛼𝛼 [deg.] 25.0 30.0 35.0
angles will reduce bending stresses cannot Addendum coefficient, ℎ𝑎𝑎𝑎𝑎 1.00 1.00 0.95 0.95 0.85 0.85
Profile shift coefficient, 𝑥𝑥𝑥𝑥 0.1599 −0.1599 0.1064 −0.1064 0.0657 −0.0657
be generalized. One of the main influences Dedendum coefficient, ℎ𝑓𝑓𝑓𝑓 1.25 1.25 1.15 1.15 1.05 1.05
on the bending stresses for the evaluated Addendum coefficient, ℎ𝑎𝑎𝑎𝑎 1.00 1.00 0.95 0.95 0.85 0.85
Root radius coefficient, 𝜌𝜌𝜌𝜌𝑓𝑓𝑓𝑓 0.317 0.317 0.21 0.21 0.09 0.09
cases is the different values of the root radius Dedendum coefficient, ℎ𝑓𝑓𝑓𝑓 1.25 1.25 1.15 1.15 1.05 1.05
Face width, 𝑏𝑏𝑏𝑏 [mm] 50.0 50.0 50.0 50.0 50.0 50.0
coefficient used for each design. Root radius coefficient, 𝜌𝜌𝜌𝜌𝑓𝑓𝑓𝑓 0.317 0.317 0.21 0.21 0.09 0.09
Figure 7 shows the loaded function of Face width, 𝑏𝑏𝑏𝑏 [mm] 50.0 50.0 50.0 50.0 50.0 50.0
transmission errors for the three cases of Table 6 shows the most important derived geometric parameters of the evaluated helical gear sets. The
transverse contact ratio, the overlap ratio, and the total contact ratio have been shown for reference.
design evaluated in this work. The maximum Table 5: General design parameters of helical gear sets.
Table 6 shows the most important derived geometric parameters of the evaluated helical gear sets. The
peak-to-peak value of transmission errors transverse contact Table ratio,6 –the
Derived
overlap geometric
ratio, andparameters of evaluated
the total contact ratio havehelical gear sets.
been shown for reference.
is decreasing when the pressure angle GEAR SET 3
GEAR SET 1 GEAR SET 2
increases. The Discrete Fourier Transform Table 6 – Derived geometric parameters of evaluated helical gear sets. (PA35)
(PA25) (PA30)
(DFT) of these functions should be evaluated GEAR SET 1 GEAR SET 2 GEAR SET 3
PARAMETER PINION GEAR PINION GEAR PINION GEAR
before drawing final conclusions in terms of (PA25) (PA30) (PA35)
Transverse contact ratio 1.299 1.158 0.999
noise and vibration excitation. PARAMETER PINION GEAR PINION GEAR PINION GEAR
Overlap ratio 1.361 1.361 1.361
Table 7 showscontact
Transverse the most important factors of influence
ratio 1.299 on the calculation of the contact and bending
1.158 0.999 stress
6: COMPARISON OF THE Total contact
numbers. Any factor ratio of influence not listed in Table 2.6607 was kept equal 2.519to those shown in Table 2.360
3.
Overlap ratio 1.361 1.361 1.361
MECHANICAL BEHAVIOR Operating pitch diameter, 𝑑𝑑𝑑𝑑𝑤𝑤𝑤𝑤 [mm] 68.107 123.445 68.107 123.445 68.107 123.445
OF CYLINDRICAL HELICAL GEARS Total contact ratio
Root diameter,
Table 7 – Factors 𝑑𝑑𝑑𝑑𝑓𝑓𝑓𝑓 [mm]
of influence on the59.386
2.660
calculation112.166
of the contact
2.519
59.759and113.393
bending stress
2.360
60.233numbers114.519
for
WITH HIGH PRESSURE ANGLES Operating pitch diameter, helical
Specific sliding at the tip [mm]
𝑑𝑑𝑑𝑑𝑤𝑤𝑤𝑤 [mm]gear 68.107
sets 123.445
0.565according0.565to AGMA
68.107
0.444
123.445
2101-D04.
0.444
68.107
0.338
123.445
0.338
Most of the published literature regard- Root diameter, 𝑑𝑑𝑑𝑑𝑓𝑓𝑓𝑓 [mm] 59.386 112.166 59.759 113.393 60.233 114.519
Specific
Table sliding
7 shows theatmost the root [mm] factors
important −1.299GEAR−1.299
of influence on the
SET −0.798
1 calculation −0.798
GEARofSET −0.511
the contact
2 and
GEAR −0.511
bending
SET stress
3
ing the application of high pressure angle Specific sliding at the tip [mm] 0.565 0.565 0.444 0.444 0.338 0.338
numbers. Any[mm]
Base pitch
PARAMETER factor of influence not listed in Table (PA25)
11.979 7 was kept equal11.394(PA30)
to those shown in Table (PA35)
3.
10.723
cylindrical gears has dealt with spur gears. Specific sliding at the root [mm] −1.299 −1.299 −0.798 −0.798 −0.511 −0.511
Not much work has been found related to Nominal circumferential force, 𝐹𝐹𝐹𝐹𝑡𝑡𝑡𝑡 [N] 26428.9 26428.9 26428.9
Table
Base6:
Table Derived
pitch [mm] geometric parameters of evaluated helical
11.979 gear sets. 11.394 10.723
the design of high pressure angle helical Radial 7force,
– Factors𝐹𝐹𝐹𝐹𝑟𝑟𝑟𝑟 [N] of influence on the calculation 13114.9of the contact 16238.0
and bending stress 19693.3
numbers for
helical gear sets according to AGMA 2101-D04.
gears. In this section, three designs of heli- Axial force, 𝐹𝐹𝐹𝐹𝑎𝑎𝑎𝑎 [N] 9619.3 9619.3 9619.3
cal gears with pressure angles of 25 degrees, Geometry factor (pitting), 𝑍𝑍𝑍𝑍𝐼𝐼𝐼𝐼 GEAR SET 1
0.171 GEAR SET 2
0.171 GEAR SET
0.162 3
12 17FTM03
30 degrees, and 35 degrees will be compared PARAMETER (PA25) (PA30) (PA35)
Geometry factor (bending), 𝑌𝑌𝑌𝑌 𝐽𝐽𝐽𝐽 0.580 0.700 0.899
regarding contact and bending stresses, and Nominal circumferential force, 𝐹𝐹𝐹𝐹 [N] 12
26428.9 26428.9 17FTM03
26428.9
loaded functions of transmission errors. Elastic coefficient, 𝑍𝑍𝑍𝑍𝐸𝐸𝐸𝐸 [N/mm2]0.5𝑡𝑡𝑡𝑡 190.20 190.20 190.20
Radial force, 𝐹𝐹𝐹𝐹𝑟𝑟𝑟𝑟 [N] 13114.9 16238.0 19693.3
Table 5 shows the general design parameters
for the helical gear designs, which were cho- Axial force, 𝐹𝐹𝐹𝐹𝑎𝑎𝑎𝑎 [N] 9619.3 9619.3 9619.3
sen similar to those of the previously ana- Geometry factor (pitting), 𝑍𝑍𝑍𝑍𝐼𝐼𝐼𝐼 0.171 0.171 0.162
Table 8 shows the safety factors for pitting and bending according to AGMA 2101-D04 for the three
lyzed designs of spur gear sets. A helix angle Geometry
designs factorgear
of helical (bending), 𝑌𝑌𝑌𝑌𝐽𝐽𝐽𝐽 analytical model0.580
sets. The does not predict any 0.700 0.899of the
benefits on the increment
of 20 degrees was chosen for all designs. pressure angle for helical gears.
Elastic coefficient, 𝑍𝑍𝑍𝑍𝐸𝐸𝐸𝐸 [N/mm ] 2 Actually,
0.5 the safety factor
190.20 for the case of higher
190.20 pressure angle
190.20is lower
Table 6 shows the most important derived than that for the designs with lower pressure angles. However, there is a substantial improvement on the
geometric parameters of the evaluated heli- safety
Table 7:factor for of
Factors bending
influencein designs with higher
on the calculation of pressure angles
the contact according
and bending to the
stress analytical
numbers model.
for helical gear sets
cal gear sets. The transverse contact ratio, the according to AGMA 2101-D04.
Table
Table 88 shows
– Safetythefactors
safety factors for pitting
for pitting and bending
and bending according
for helical geartosets
AGMA 2101-D04
according tofor the three
AGMA 2101-D04.
overlap ratio, and the total contact ratio have
designs of helical gear sets. The analytical model does not predict any benefits on the increment of the
been shown for reference.
pressure angle for helical gears. Actually, the safety factor forGEAR
the case
SETof1higher
GEAR pressure
SET 2 angle
GEAR is SET
lower3
Table 7 shows the most important factors than that for the designs with lower pressure angles. However, there (PA25) (PA30)
is a substantial (PA35)
improvement on the
PARAMETER
of influence on the calculation of the contact safety factor for bending in designs2 with higher pressure angles according to the analytical model.
Contact stress number, 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻 [N/mm ] 1282.46 1280.53 1316.14
and bending stress numbers. Any factor of
influence not listed in Table 7 was kept equal Allowable contact stress number, 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃 [N/mm2] 1550.00 1550.00 1550.00
Table 8 – Safety factors for pitting and bending for helical gear sets according to AGMA 2101-D04.
to those shown in Table 3. Effective allowable contact stress number, 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃eff [N/mm ]
2
1745.00 1745.00 1745.00
Table 8 shows the safety factors for pitting Safety factor (pitting), 𝑆𝑆𝑆𝑆𝐻𝐻𝐻𝐻 GEAR SET 1 GEAR
1.36 SET 2 GEAR
1.36 SET 3
1.33
and bending according to AGMA 2101-D04 PARAMETER (PA25) (PA30) (PA35)
Bending stress number, 𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹 [N/mm2] 214.15 177.35 138.02
for the three designs of helical gear sets. The Contact stress number, 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻 [N/mm2] 1282.46 1280.53 1316.14
Allowable bending stress number, 𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃 [N/mm2] 450.00 450.00 450.00
analytical model does not predict any ben- Allowable contact stress number, 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃 [N/mm2] 1550.00 1550.00 1550.00
efits on the increment of the pressure angle Effective allowable bending stress number, 𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃eff [N/mm2] 522.00 522.00 522.00
Effective allowable contact stress number, 𝜎𝜎𝜎𝜎𝐻𝐻𝐻𝐻𝑃𝑃𝑃𝑃eff [N/mm2] 1745.00 1745.00 1745.00
for helical gears. Actually, the safety factor Safety factor (bending), 𝑆𝑆𝑆𝑆𝐹𝐹𝐹𝐹 2.44 2.94 3.78
Safety factor (pitting), 𝑆𝑆𝑆𝑆𝐻𝐻𝐻𝐻 1.36 1.36 1.33
for the case of higher pressure angle is lower
than that for the designs with lower pressure Bending
Table stressfactors
8: Safety number, 𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹 [N/mm
for pitting and2]bending for helical gear sets according
214.15 to AGMA
177.35
2101-D04. 138.02
Allowable bending stress number, 𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃 [N/mm2] 450.00 450.00 450.00
36     gearsolutions.com Figure 8 shows the evolution of the contact pressure (CPRESS in Abaqus) for the middle pair of contact
Effective
teeth. allowable bending
It corresponds with thestress number,
third tooth 𝜎𝜎𝜎𝜎𝐹𝐹𝐹𝐹𝑃𝑃𝑃𝑃eff [N/mm
in a model
2]
of five pairs 522.00
of 522.00
teeth. Pressure 522.00
angle of 30 degrees
yields slightly lower maximum contact pressure than the reference design with a pressure angle of 25
 Figure 8 – Evolution of the maximum contact pressure on the contact surfaces
of the middle pair of contacting teeth.

Figure88:– Evolution
Figure Evolutionofofthe
themaximum
maximum contact pressure
contact on the
pressure contact
on the Figure
surfaces
contact of 9 – Figure
surfaces Evolution of the maximum
9: Evolution Von Mises
of the maximum stressstress
Von Mises on the
oncontacting surfaces
the contacting of the
surfaces of pinion.
of the middle
the middle pair of contacting teeth.pair of contacting teeth. the pinion.
Figure 9 shows the evolution of the maximum Von Mises stress on the contacting surfaces of the pinion,
no matter in which tooth it appears. Notice that the evolution is a periodic function as expected, due to the
evaluation ofanalytical
two cycles of meshing.
model forThe
thedesign with the higher
determination pressure
of the anglestress
contact of helical gears shows the
number.
higher Von Mises stresses, also in agreement with Figure 8, which shows higher values of contact
Figure 9 shows the evolution of the maximum Von Mises stress
pressure for that design. Designs with 25 and 30 degrees of pressure angle show similar maximum levels
on theIncontacting
of contact stresses. surfaces
general, as shown of the8pinion,
in Figures and 9, nono matter in
advantages arewhich tooth
observed it high
for using
appears.
pressure angles Notice
in helical that the
gear drives evolution
in terms is astresses
of contact periodic
andfunction as expected,
contact pressure on the gear tooth
surfaces. due to the evaluation of two cycles of meshing. The design with the
higher-pressure angle of helical gears shows the higher Von Mises
Figure 10 – Evolution of maximum principal stress (bending stress)
at the fillet surface of one tooth of the pinion. stresses, also in agreement with Figure 8, which shows higher values
of contact pressure for that design.14 Designs with 25 and 30 degrees of 17FTM0
Figure 10 shows the evolution of the maximum principal stress (larger tensile stress) at the fillet surface pressure
of angle show similar maximum levels of contact stresses. In
one tooth of the pinion. The maximum bending stress for higher pressure angle gears, contrary to what is
general, as shown in Figures 8 and 9, no advantages are observed for
predicted by the analytical models, is higher for the design with 35 degrees of pressure angle. Designs of
using high pressure angles in helical gear drives in terms of contact
25 and 30 degrees yield similar levels of maximum principal stresses at the fillet. No advantage is
observed for the design with higher pressure angles in terms of bending stresses. Therefore, not only stresses
has and contact pressure on the gear tooth surfaces.
the safety factor not increased, but according to the finite element method, it has been reduced due to Figure 10 shows the evolution of the maximum principal stress
higher values of bending stresses. The analytical model to calculate the bending stress seems not to(larger tensile stress) at the fillet surface of one tooth of the pinion. The
Figure 9
capture the– Evolution
Figure
increment of10
of the maximum
– Evolution
stresses Von
toof Mises
stressstress
maximum on the
principal contacting
stress (bending surfaces
stress) ofhigher
the pinion.
Figure 10: Evolution of due
maximum larger
principal concentration
stress (bending factors
stress)in designs with
at the fillet maximum bending stress for higher pressure angle gears, contrary
pressure angles, where small atroot
theradius
fillet surface of one
coefficients are tooth
used. of the pinion.
surface of one tooth of the pinion. to what is predicted by the analytical models, is higher for the design
Figure 9 shows the evolution of the maximum Von Mises stress on the contacting surfaces of the pinion,
no matter in which tooth it appears. Notice that the evolution is a periodic function
Figure 10 shows the evolution of the maximum principal stress (larger tensile stress) at the fillet surfaceas expected, due with
to theof 35 degrees of pressure angle. Designs of 25 and 30 degrees
evaluation
one tooth of two cycles of
the pinion. The meshing.
maximum The design stress
bending with theforhigher
higherpressure
pressureangle
angleofgears,
helicalcontrary
gears shows
to whatthe
is similar levels of maximum principal stresses at the fillet. No
yield
higher Vonby
predicted Mises stresses, models,
the analytical also in agreement
is higher for with
theFigure
design8,with
which35shows
degrees higher values of
of pressure contact
angle. Designs of
advantage is observed for the design with higher pressure angles in
pressure
25 and 30fordegrees
that design.
yieldDesigns with 25
similar levels of and 30 degrees
maximum of pressure
principal stresses angle
at theshow similar
fillet. No maximum
advantage is levels
ofobserved
contact stresses. In general,
for the design as shown
with higher in Figures
pressure angles8 in and 9, no
terms ofadvantages are observed
bending stresses. for using
Therefore,
terms
high
not only has
of bending stresses. Therefore, not only has the safety factor
pressure angles
the safety factorinnot
helical gear drives
increased, in terms of
but according to contact
the finitestresses
elementand contact
method, pressure
it has on the gear
been reduced not
to increased, but according to the finite element method, it has been
duetooth
surfaces.
higher values of bending stresses. The analytical model to calculate the bending stress seems not toreduced due to higher values of bending stresses. The analytical model
capture the increment of stresses due to larger stress concentration factors in designs with higher
to calculate the bending stress seems not to capture the increment
pressure angles, where small root radius coefficients are used.
of stresses due to larger stress concentration factors in designs with
14 higher pressure angles, where small root radius coefficients are used.
17FTM03
Figure 11 shows the loaded function of transmission errors for
helical gears with different pressure angles. It can be observed that
the peak-to-peak maximum transmission errors are lower for the
design with higher pressure angles. Noise and vibration excited by
transmission errors might be lower for high pressure angle helical
Figure 11 – Loaded function of transmission errors for helical gears gear designs. However, the difference is slight and might not be
Figure 11: Loaded function of transmission errors for helical gears with different
with different pressure angles. noticeable. In Figure 11, it can be observed that the loaded function
pressure angles.
of transmission errors is not exactly periodic near the initial and
final contact points. This is a characteristic of finite element models
angles. However, there is a substantial 15 improvement on the safety 17FTM03 with boundary conditions slightly affecting the obtained results. The
factor for bending in designs with higher pressure angles according use of finite element models of seven pairs of contacting teeth for
to the analytical model. helical gears would improve the periodicity of the loaded function of
Figure 8 shows the evolution of the contact pressure (CPRESS in transmission errors. However, it is not expected that different results
Abaqus)Figure for11the middle
– Loaded pair ofofcontact
function teeth.errors
transmission It corresponds
for helical gearswith the would be obtained by using those models.
third tooth in a modelwith of five pairspressure
different of teeth.angles.
Pressure angle of 30 degrees
yields slightly lower maximum contact pressure than the reference 7: CONCLUSIONS
design with a pressure angle of 25 degrees. As shown in Figure 8, the Based on the results obtained in this work, the following conclusions
design with the pressure angle of 35 15 degrees shows a substantial incre- 17FTM03 can be drawn:
ment on the contact pressure, which is not entirely predicted by the  High pressure angle spur gears show a minor reduction in con-
June 2018     37
tact stresses and contact pressure. The maximum values for both con- Pressure Angle Gears, Transmission and Driveline. 

tact stresses and the contact pressure are obtained at the lowest point [ 5 ] Kapelevich, A.L., 2000, Geometry and Design of Involute Spur Gears with
of single tooth contact, as considered by the analytical methods. Asymmetric Teeth, Mechanism and Machine Theory, 35(1), pp.117–130. 

Maximum bending stresses for spur gears with a high-pres- [ 6 ] Fuentes, A. and Gonzalez-Perez, I. and Sanchez-Marin, F.T. and Hayasaka,
sure angle might not only be reduced, but in some cases, might be K., 2012, On the behaviour of asymmetric cylindrical gears in gear trans-
increased. An example of design in which the maximum bending missions, Processing of the FISITA 2012 World Automotive Congress 193,
stresses at the pinion fillet increased was shown. The influence of Vol. 5., pp.143–150. 

small root radius coefficients on bending stresses for high pressure [ 7 ] Hayer, L., 1986, Advanced Transmission Components Investigation, Sikorski
angle gears should be further evaluated. Aircraft Division, USAAVRADCOM TR-82-D-11. 

High pressure angle helical gears yield higher maximum con-
[ 8 ] Sanders, A. and Houser, D.R. and Kahraman, A. and Harianto, J. and Shon,
tact pressure, higher maximum Von Mises contact stress, and higher S., 2011, An Experimental Investigation of the Effect of Tooth Asymmetry
maximum principal stresses at the fillet area. No advantage was and Tooth Root Shape on Root Stresses and Single Tooth Bending Fatigue
found for using or recommending high pressure angle helical gears. of Gear Teeth, Proceedings of the ASME 2011 International Design
Only the loaded function of transmission errors showed a peak-to- Engineering Technical Conferences and Computers and Information in
peak value smaller than that obtained for designs with lower pres- Engineering Conference. 

sure angle helical gears. [ 9 ] American Gear Manufacturers Association, 2004, Fundamental Rating
Whereas the analytical models yielded lower bending and con- Factors and Calculation Methods for Involute Spur and Helical Gear Teeth,
tact stresses for the designs with higher pressure angles, the numeri- Metric Ed., ANSI/AGMA 2101-D04. 

cal analysis of stresses by the finite element method applied to two [ 10 ] American Gear Manufacturers Association, 2015, Geometry Factors for
cycles of meshing yielded higher values of stresses. The causes of this Determining the Pitting Resistance and Bending Strength of Spur, Helical
difference should be further investigated and incorporated into the and Herringbone Gear Teeth, AGMA 908-B89. 

rating methods.  [ 11 ] Sheveleva, G.I. and Volkov, A.E. and Medvedev, V.I., 2007, Algorithms for
Analysis of Meshing and Contact of Spiral Bevel Gears, Mechanism and
BIBLIOGRAPHY Machine Theory, 42(2), pp.198–215. 

[ 1 ] Handschuh, R.F. and Zakrajsek, A.J., 2010, High Pressure Angle, Preliminary
[ 12 ] Fuentes, A. and Ruiz-Orzaez, R. and Gonzalez-Perez, I., 2014, Computerized
Results, NASA/TM- 2010-216251. 

Design, Simulation of Meshing and Finite Element Analysis of Two Types of
[ 2 ] Handschuh, R.F. and Zakrajsek, A.F., 2011, High-Pressure Angle Gears: Geometry of Curvilinear Cylindrical Gears, Computer Methods in Applied
Comparison to Typical Gear Designs, Journal of Mechanical Design, 133. 
 Mechanics and Engineering, 272, pp.321–339.
[ 3 ] Miller, R., 2016, Designing Very Strong Gear Teeth by Means of High [ 13 ] Litvin, F.L. and Fuentes, A., 2004, Gear Geometry and Applied Theory, 2nd
Pressure Angles, AGMA Technical Paper 16FTM13. 
 Ed. Cambridge University Press, New York. 

[ 4 ] Herscovici, S., 2006, The Benefit of High Pressure Angle Gears Vs. Low [ 14 ] 17 17FTM03

ABOUT THE AUTHORS

Dr. Alfonso Fuentes-Aznar is with the Rochester Institute of Technology, and Dr. Ignacio Gonzalez-Perez is with the Polytechnic University of
Cartagena. This article published by permission of the American Gear Manufacturers Association, copyright © 2017, 17FTM03, ISBN: 978-1-
55589-537-2. The statements and opinions contained herein are those of the author and should not be construed as an official action or opinion
of the AGMA.

38     gearsolutions.com
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June 2018     39
 EVALUATING
THE UNKNOWN
GEOMETRY OF
HIGH
ACCURACY
GEARING

40     gearsolutions.com
Finding the addendum modification coefficient using the
base tangent length (BTL) method is found to be useful
for gear parameter evaluation of an unknown gear.
By PRASMIT KUMAR NAYAK, A. VELAYUDHAM and C. CHANDRASEKARAN

E
valuation of geometry of used and broken gear parts. Suitable algorithms have been developed for
is a seldom practice followed in the fields such extracting and inspecting the mechanical component.
as maintenance repair and recycling. Although Data have been extracted from the image and used
gear  calculations and main parameters are to construct a 3D model and 2D drawing. It has been
standardized, this task can be complicated, espe- observed that the detecting of straight lines, holes,
cially when there is no information about mating and circles are faster and more reliable. However, the
gear and gearbox assembly, change in the accuracy accuracy of extracted data from the images are very
of used gears due to heavy wear, and sometimes the important for reproducing the component. Charles
gear geometry probably is non-standard. Such situa- D. Schultz, 2010, has brought out a methodology for
tion calls for effective and accurate methods of gear the reliable measurement, evaluation, re-design, and
profile geometry evaluation. Different methods like manufacture of replacement parts for gear boxes and
reverse engineering, iterative process, and analytical industrial machinery.
methods are being followed in gear industries. In the estimation of gear tooth geometry, profile
Apart from these, a diverse number of CNC gear shift/modification factor is an imaginary parameter
generative testing equipment and coordinate mea- used to represent the thickness of gear tooth. Negative
suring machines are available profile shift leads to smaller tooth
in the industry to inspect the thickness and tip diameter and
gears using fully automated Gear modifications positive profile shift corresponds
gear measurement cycles. But in
these advanced gear-measuring
are carried out by to the larger tooth thickness and
tip diameter. It is to be noted that
machines, the profile of the tooth
can be checked and compared
different means profile shift, real tooth thick-
ness, and real tip diameter may
with a flank topography refer- and each would not match precisely, due to vari-

influence different
ence, and by means of a trial-and ous design and technological con-
error procedure, it is possible to siderations. Therefore final draw-
obtain an approximate geometry
of the analyzed gears [Kumar,
parameters. ings of spare parts must contain
tooth thickness and tip diameter
2014]. Moreover, some advanced based  on direct measurements
measurement machines have incorporated special pro- and calculations of meshing quality (interference,
grams for measuring gears with unknown parameters undercut, overlap, minimum tooth thickness at the
and determining some important data of the basic tip circle of a gear, etc.).
gear geometry [Grimsley, 2003]. Unfortunately, these Of the above methods, the analytical method is
machines are costly and often inaccessible to the com- more accurate, scientific, and does not involve com-
pany or factory involved with gear remanufacturing. plex measurements and iterations. Hence, the main
Because of this, several researchers [Innocenti, 2007; focus of this paper is to investigate the used and
Belarifi et al, 2008; and Schultz, 2010] have proposed broken spur gear of a CNC machining center spindle
alternative procedures to determine the unknown gearbox and estimate the basic gear parameters using
gear geometry. standard measuring instruments followed by the use
Gonzalez et al, 2016, have proposed a procedure to of analytical gear equations as given in DIN 3960 and
obtain the fundamental gear parameters using con- graphical construction. Typically, the evaluation of
ventional measurement tools. In their approach, it is gears used in the old gearbox of a CNC machining
assumed that the involute surface of the flank of a center, implies challenges to the engineers, since the
cylindrical gear can give information about the basic gears used would be of higher accuracy, and the back-
gear tooth data needed to determine the unknown lash would be minimum. In general CNC machine tool
gear geometry. Jadhav and Sandooja, 2012, have adopt- manufacturers use modified gears.
ed a step wise analytical approach to find out the basic Gear modifications are carried out by different
gear parameters for an unknown gear pair, which means and each would influence different parame-
eliminated frequent trial and errors, iterations, and ters. Both the gear and pinion can be provided positive
complex measurements. Alshennawy, 2014, has adopt- or negative correction. Gears are usually modified to
ed a machine vision system coupled with CCD camera avoid undercutting or to maintain a desired center
as a reverse-engineering tool for developing gear spare distance in a gear box. In addition to that, the gear
June 2018     41
 Theform
the module is anchart
of flow important parameter
in Figure 3. Withinreferencedefining to theDIN
size3960.
of gear tooth. It cannot
measured directly from the gear, but can be calculated using equations of base tan
Module
Module
As per DIN 3960, the expression for finding the base tangent length is mentioned
The module is an important parameter in defining the size of gear tooth. It cannot
The module
(1) and is an important
(2). Using these twoparameter
equations,inthe defining the size
expressions forofmodule
gear tooth.
can beIt obtaine
cannot
and pinion are now positively corrected to achieve several benefi- measured
length. directly
As(3)perandDIN from
3960,the
the gear, but can be
expression for calculated
finding using equations of base tan
measured
equation directly from
(4). the
Further gear,
the but can be
equation (3) and (4) the
calculated base
using
are tangent
equations
combined andofa base
singletan
e
As per DIN 3960, the in expression for(1)finding theUsing
base tangent length is mentioned
cial effects. These positively corrected gears have better strength at As per DIN
is derived
length to3960,
find out
is mentioned the the
expression
standardfor
equation finding
module. and (2). the baseangle
Pressure tangent
these length
is two
also an is mentioned
unknown
equa- par
(1) and (2). Using these two equations, the expressions for module can be obtained
the root and the flank of the tooth. Due to positive correction, the (1)
tions,andthe
standard (2). Using angles
pressure
expressions thesefortwo
and equations,
the themodule
measured the
can expressions
base tangentfor
be obtained module
lengths
as arecan
equation be obtained
substituted in
equation (3) and (4). Further the equation (3) and (4) are combined and a single eq
tooth thickness at the root increases, thereby resulting in greater equation
and
(3) the
and (3)Further,
(4). andstandard
nearest (4).equations
Further
modulethe(3)equation
is derived.
and (4) (3)
are and (4) are combined
combined, and a and a single eq
single
is derived to find out the standard module. Pressure angle is also an unknown para
load carrying capacity. In case of a corrected profile, the active pro- is derived (7)
equation to find out the to
is derived standardout module. Pressure angle is also an unknown para
standard pressure angles andfind the measured the standard
base tangentmodule.
lengths Pressure
are substituted in
files formed from the involute curve are generated from the same standard
angle pressure
is nearest
also anstandardangles and
unknown parameter.the measured base tangent lengths
The standard pressure angles are substituted in
and the [(𝑘𝑘 − 0.5module
) 𝜋𝜋 + 𝑍𝑍is derived.
𝑊𝑊"#the
and = nearest
𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐standard module is# 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖] + 2 𝑋𝑋# 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠-----------------
derived. (1)
base circle, but this time a different portion of the curve, which is and the measured base tangent lengths are substituted in equation
farther away from the base circle. The main advantage of these gears 𝑊𝑊
(7),"< = 𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 [( 𝑘𝑘 − 0.5
and the nearest standard module ) 𝜋𝜋 + 𝑍𝑍< 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 ] + 2 𝑋𝑋
is derived. < 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠---------------- (2)
with an involute profile is that even at an extended center distance, 𝑊𝑊"# = 𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐[(𝑘𝑘 − 0.5) 𝜋𝜋 + 𝑍𝑍# 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖] + 2 𝑋𝑋# 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠----------------- (1)
𝑊𝑊"# = 𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐[(𝑘𝑘 − 0.5) 𝜋𝜋 + 𝑍𝑍# 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖] + 2 𝑋𝑋# 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠----------------- Equation 1 (1)
and the
it continues to follow gear
the law of tooth also
conjugate does
action andnot become
continues to significantly
𝑊𝑊 =
weak.
𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐
This correction is used
[(𝑘𝑘 − 0.5) 𝜋𝜋 + 𝑍𝑍< 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 ] + 2 𝑋𝑋< 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠---------------- (2)
where,
𝑊𝑊 "<
"< = 𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐[(𝑘𝑘 − 0.5) 𝜋𝜋 + 𝑍𝑍< 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 ] + 2 𝑋𝑋< 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠---------------- Equation 2 (2)
transform uniformin the casevelocity
angular whereratio.
the reduction ratio is very large.
In another type of correction, the mating pair of gears receives 𝑊𝑊"# - Actual base tangent length of gear over 𝑘𝑘# no. of teeth
where,
Wwhere,
equal correction factors, but these two
Description of component factors are algebraically of 𝑊𝑊k1"<–- Actual
where, Actual base tangentlength
base tangent length ofofpinion
gear over
over 𝑘𝑘k<1 no.
no. of
of teeth
teeth
opposite signs. Normally, the pinion and gear are provided with posi- W𝑊𝑊k2 -
– Actual
Actual base
base tangent
tangent
=>? @=>?A? length
lengthof gear
of over
pinion over
𝑘𝑘 no. of
k 2 teeth
no. of teeth
𝑊𝑊"# - Actual
𝑚𝑚# = base tangent length of gear over 𝑘𝑘#
no. of teeth
-------------------------------------------- (3)
There
tive and negative correction, was a Inrequirement
respectively. to reverse
this case, the center dis- "#
engineer, reproduce
BCDEF and replace #
𝑊𝑊"< - Actual base tangent length of pinion over 𝑘𝑘< no. of teeth a
tance remains unaltered, it remains the same. Thicker 𝑊𝑊"< - Actual
=>G @=base tangent length of pinion over 𝑘𝑘< no. of teeth
broken gear component of an pinion teeth
old gearbox of
𝑚𝑚< a = typical >GA?horizontal
=>? @=>?A? CNC Machining
-----------------------------------------------------
Equation 3 (4)
are ensured, and the gear tooth also does not become significantly 𝑚𝑚B CDEF
= = @= -------------------------------------------- (3)
andcentre.
the gear tooth also does
A schematic of the notgear
become pair significantly
is illustrated 𝑚𝑚#weak.
#
=in Fig.
>?
This
BCDEF
BCDEF <1.correction
>?A?
The is used
machine was
-------------------------------------------- (3)
weak. This correction is used in the case where the reduction ratio = @=
manufactured
case whereinthethe year 1983 ratioand no large.
spare𝑚𝑚# < =
=was
=>G @=>?
= H@=
>?A?
available ---------------------------------------------------
I -----------------------------------------------------
as the machine tool (5)
is very large.in the reduction is very (4)
>GA?
𝑚𝑚 BCDEF Equation 4
𝑚𝑚<< = >GB CDEF >GA?
----------------------------------------------------- (4)
manufacturer closed down their company, thus necessitating B CDEF
@=J
G
< the proposed study.
Assume
𝑚𝑚 <
= H𝑚𝑚
=>? ?
= >?A? --------------------------------------------
Equation 5
---------------------------------------------------
I< axis (6)
(5)
DESCRIPTION OF COMPONENT
The centreofdistance
Description component between axis of the gear𝑚𝑚#broken # <
= H and BCDEF the
=>?@=J >?A?
G of mating gear is
I --------------------------------------------------- (5)
BCDEF
205 ±0.036
There was a requirement mmengineer,
to reverse as shown in Fig.and
reproduce, 1. replace Assume 𝑚𝑚 = J G
? Equation 6
-------------------------------------------- (6)
There was a requirement to reverse
a broken gear component of an old gearbox of a typical horizontal engineer,
Assume
[INSERT𝑚𝑚FIGURE
reproduce
J?G
= JG 3] and replace a
-------------------------------------------- (6)
JG
CNC machiningbroken gear
center. component
A schematic of the of
gearan old
pair gearbox of Then
is illustrated a typical horizontal (=>? @=>?A?)G
CNC Machining
Then 𝑚𝑚 in = (= Equation 7
------------------------------------------------------
centre.
in Figure 1. The A schematic
machine of the
was manufactured gearandpair
in 1983 is illustrated
no spare
[INSERT FIGURE Fig.
>G @= 1.
3]
>GA?
The
) BCDEF machine was
was available as the machine tool manufacturer closed down the
manufactured in the year 1983 and no spare was available [INSERT FIGURE 3]as the machine tool
(=>? @=>?A?)G
company, thus necessitating the proposed study. The center distance [INSERT
ThenFrom 𝑚𝑚 = TABLE
Table
2,>? 2]
it@=is observed
G that for pressure angle of 20 degrees,
------------------------------------------------------
manufacturer closed down their company, thus Then
the
necessitating
𝑚𝑚 = (=
difference
(=
>G @=>GA?
between
the
>?A?) proposed
calculated
study.
) BCDEF ------------------------------------------------------
andpressure
standard modules
between axis of the gear broken and the axis of the mating gear is From the Table>G2, it>GA? is observed that for of 20°, isthemini-
is angle difference betw
(= @= ) BCDEF
The centre distance between axis of the gear broken
mum. and
Hence, the
it is axis
verified of mating
that the gear
pressure angle and
205, ±0.036 mm as shown in Figure 1. calculated
[INSERT TABLE 2] and standard modules is minimum. Hence it isthe module
verified ofthe pressur
that
205 ±0.036viewmm asbroken
shown in is
Fig. 1. in Figure both [INSERT gear TABLE
and 2] are 20 degrees and 3.5 mm respectively.
The photographic of the gear shown the module of pinion
both gear and pinion are 20° and 3.5 mm respectively.
From the Table 2, it is observed that for pressure angle of 20°, the difference betw
2.The basic data of the gear pair are mea- From the Table 2, it is observed that for pressure angle of 20°, the difference betw
Addendum
calculated andModification
standard modulesCoefficient
is minimum. Hence it is verified that the pressure
sured using standard measuring instru- calculated and standard modules
the module of both gear ADDENDUM
and pinion are MODIFICATION
is minimum.
20°
Hence it is verified that the pressure
andmodule,
3.5 mm respectively.
ments as seen in Table 1. The common data After
the finding
module of the
bothvalues of pressure
COEFFICIENT
gear and pinion are angle
20°and
and 3.5 mm pitch circle diameters are c
respectively.
that can be directly measured are number using
Addendumstandard formula.
Modification The center
Coefficient
After finding distance
the is
valuesequal
of to half
the of theangle
pressure sum of referenc
Addendum Modification Coefficient
From the calculations it is found that the center distance is 199.5 mm. If it is less
of teeth, tip diameter, and root diameter for After finding the values of and pressure
module, angle andcircle
pitch module, pitch circle
diameters arediameters
cal- are c
After finding
than the the values
measured value,ofthere
pressure angle and
is a positive ormodule,
negativepitch circle on
correction diameters
either orare
botc
both the gear and pinion. The base tangent using standard formula. The center
culated distance
using is equal
standard to half of
formula. Thethecenter
sum of referenc
using standard
and pinion. formula.
In the case ofThe center correction,
positive distance is gears
equal are
to half of the
pulled apartsum byofanreferenc
amount
length across a fixed number of teeth (num- From the calculations it is found that
distance the center
is equal to halfdistance
of theis 199.5of mm. If it is less o
From
times the calculations
module. In this it is foundhigher
condition that theamount
center distance
of backlash issum
199.5
usually refer-
mm. If it isTheref
results. less o
ber of teeth to be obtained using DIN 3960) than the measured value, there is a positive or negative correction on either or both
than the measured value,ence therediameters.
is a positiveFrom the calculations,
or negative correction on it either
is or both
and pinion. In the case offound positive correction, gears are pulled apartmm.by an amount
was measured using a flange micrometer. and pinion. In the case of positive thatcorrection,
the center gears are pulled
distance apart by an amount
is 199.5
times module. In this condition higher amount of backlash usually results. Therefo
The module of an unknown gear cannot times module. In this condition higher
If it is less amount
or more thanof backlash
the measuredusually results. Therefo
value,
be measured directly. It can be derived from there is a positive or negative correction on
Fig. 1. Schematic of gearbox
base tangent length. In the case of a correct- either or both the gear and pinion. In the
The photographic view of the broken gear is shown in Fig.
ed gear, the profile modification factor is to case2.The basiccorrection,
of positive data of gears are pulled
be derived. This factor is found out from the apart by an amount ‘X1+ X2’ times module. In
the gear pair are measured utilizing standard measuring instruments are given in
measured base tangent length. It is also relat- this condition, a higher amount of backlash
ed to the centerTable.
distance1.between
The common
the gear data which can be directly measured areusually number of teeth,
results. Therefore, tip to minimize the
diameter and root
pair. An alternative method is also adopted diameter for both the gear and pinion. The base tangent length
backlash, the gear pairs are brought closer
across
to find the profile a fixedfrom
modification number
the tip of teeth
Figure 1:(number
Schematic ofof teeth to be obtained using
gearbox. DIN 3960) was
to an intermediate value (center distance
diameter of the gear and the pinion. Fig. 1. Schematic of gearbox modification coefficients, ‘y’ to get a new
center distance.)
METHODOLOGY OF GEAR
The photographic view of the broken gear is shown in Fig. 2.The basic
For the data gear
modified of pair, the center dis-
GEOMETRYthe EVALUATION
gear pair are measured utilizing standard measuring instruments are given in of pitch circle radii
tance is equal to the sum
The procedure Broken teeth
Table.finding
for 1. Theout the profile
common data which can be directly measured are number of gear and of pinion
teeth,and tipthe sum of the center
modification factor and other data is illus- distance modification coefficient times the
diameter and root diameter for both the gear and pinion. The base tangent length
trated in Figure 3, with reference to DIN module. The center distance coefficient ‘y,’
3960. across a fixed number of teeth (number of teeth to be obtained using DIN pressure
working 3960) was angle (αw), and the sum of
modification coefficients, X1+ X2 (theoretical
MODULE value) are calculated using equations (8) to
The module is an important parameter in (10) as per DIN 3960.
defining the size of a gear tooth. It cannot be To derive the modification coefficient,
Broken teeth
measured directly from the gear but can be different methodologies are available. But,
calculated using equations of base tangent Fig.2 Photographic
Figure view
2: Photographic view of broken
of broken gear. gear since the study involves remanufacturing of
42     gearsolutions.com
 @# CDEF CDEF
between the gear pair. An alternative method is also adopted to find the 𝛼𝛼profile
P = 𝛼𝛼
cos
P = T T XGU
cosGU@#O# X -------------------------------------
-------------------------------------(9) (9)
modification from the tip diameter of the gear and the pinion. V? WVG V? WVGO#
Table 1 Data measured from gear pair (YZ[FM @YZ[F)
(YZ[F @YZ[F)
𝑋𝑋# + 𝑋𝑋𝑋𝑋
< #=+ 𝑋𝑋<< \LZF
= M
𝑍𝑍< )# + ------------------------------------
(𝑍𝑍# + (𝑍𝑍 -
𝑍𝑍< ) ------------------------------------ -(10) (10)
Parameter Gear Pinion ADDENDUM< \LZF
MODIFICATION COEFFICIENT
No. of teeth 𝑍𝑍 59 55 USING THE BTL METHOD
Across 8 teeth - 82.73 Across 7 teeth - 71.41Addendum
UsingModification
Addendum Coefficient
Modification
the equations (1) and (2),Using
Coefficient the BTL
Using
modification Method
the BTL Method
coefficients (X1, X2 ) are
Base tangent length (mm) 𝑊𝑊$
Across 9 teeth - 93.06 Across 8 teeth - 81.76 obtained
Tip Diameter (mm) 𝑑𝑑& 219.35 201.6
Using the
Using the from
equations (1)the
equations measured
and(1)(2)and BTL value.
modification The measured
coefficients
(2) modification (X1, X2(X
coefficients BTL
) are
1, X
values from th
obtained
2) are obtained f
and
measured calculated
BTL value. values
The of modification
measured BTL coefficients
values and (X
calculated
measured BTL value. The measured BTL values and calculated ,
1 2 X )
valuesareofgiven
modification
values of modi
Root Diameter (mm) 𝑑𝑑' 203.6 186
(BCD EBCDFD)L
in Table
coefficients X2)(Xare
(X1,3.*
coefficients given
1, X 2) arein Table
given in 3.
Table 3.
= (B ------------------------------------------------------
Diameter over pin (Ø 7mm) 𝑑𝑑' 223.36 207.61 (7)
[INSERT TABLE 3]
CLFD ) GHIJK
CL EBCentre [INSERT TABLE 3]
distance (mm) 𝑎𝑎) 205 ADDENDUM MODIFICATION COEFFICIENT
Methodology of gear geometry evaluation Addendum
USINGModification Coefficient
THEModification
Addendum TIP DIAMETER Using the
METHOD
Coefficient Tipthe
Using Diameter Method
Tip Diameter Method
Table 1:
Addendum Table
Data
modification 2.
measured Calculated
from
coefficient using values
gear pair. of module
BTL method Usingis the equations (11)(11)
and (12) modification coefficients (X1, X2)(X
(Xare
The procedure for finding out the profile modification factor and other data Using
Using equations
the equations and
(11) and(12),
(12)modification
modificationcoefficients
coefficients Xobtained
1,, X 2 )) are from
are obtaine
illustrated
Using in theequations
the form of flow
(1)chart
and in(2)Fig. 3. With reference
modification to DIN (X
coefficients 3960.
1, X2) are measured
obtained Tip
measured
obtaineddiameter
Tip
from value.
diameter
the The
measured measured
value. The
tip Tip diameter
measured
diameter Tip
value. values
diameter
The and
values
measuredcalculated
and tip value
calculated
from the measured Pressure
BTL value. The measured BTLDifference
values and calculated modification
valuesdiameter
of coefficients
modification X2)(Xare
(X1,calculated
coefficients
values and given
1, X 2) arein Table
given
values of in 4.
Table 4.
modification coefficients
ModuleSerial Module
modification moduleangle
Thecoefficients
is an , 'α'in
X2) are given
(X1important in Table
parameter (calculated
3.
in defining the size ofand
gear tooth. It (X1, X2 ) are given in Table 4.
cannotNo. directly from the'm' mm
Table 3 degree
be measured
Calculation gear, but can standard
of modification be calculated module)
coefficient based using
on BTL equations of
𝑑𝑑L# =𝑍𝑍𝑑𝑑# 𝑚𝑚+(1#+ 𝑦𝑦(− 𝑋𝑋<𝑦𝑦)𝑚𝑚
− 𝑋𝑋< )𝑚𝑚 ----------------------------------------- (11
base tangent length. As per DIN 3960, the expression for finding the base tangent L# =𝑍𝑍 𝑚𝑚+ 1+ -----------------------------------------
Equation 11
length is 1mentioned 17.5
in equation 3.4410
(1) and (2).
Base Tangent length Using these0.0590
two equations, the (1<+
𝑑𝑑L< =𝑍𝑍𝑑𝑑< 𝑚𝑚+=𝑍𝑍 𝑦𝑦(−
𝑚𝑚+ +#𝑦𝑦)𝑚𝑚
1 𝑋𝑋 − 𝑋𝑋# )𝑚𝑚 ----------------------------------------- (12
-----------------------------------------
Equation 12
expressions for module can be obtained as equation (3) and (4). Further the L<
Addendum 2
modification 20
coefficient
equation (3) and (4) are combined 3.4924
using
Measured BTL
value
and a single method 0.0076
Modification
equation co-efficient
(7) is derived to find out the
Gear VALIDATION OF ADDENDUM MODIFICATION
standard module. Pressure angle is modification
also an unknown parameter. The standard
Using 3 9 teeth)22.5
the
(across equations (1) and
pressure angles and the measured𝑊𝑊base
(2)3.5521
$* =93.06 𝑋𝑋*0.0521
coefficients
tangent lengths are
(X 1, X 2) are[INSERT
obtained TABLETABLE
[INSERT
substituted in equation COEFFICIENT
= 0.9728 4] 4]
from the measured BTL value. The measured BTL values and calculated values of
(7) andPinion
the nearest standard
(across 8
Table coefficients
2: It is here observed
module is derived. Validation of
Validation Addendum
of Addendum
The modification Modification Coefficient
Modification
coefficients Coefficient
obtained from the two different
modification (X1, X2that
) arefor
𝑊𝑊 pressure
given
$A angle of
in Table
=81.76 3. 20°, the 𝑋𝑋A difference
= 0.6509 between
teeth)
calculated and standard
𝑊𝑊$* = 𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐[(𝑘𝑘 modules
− 0.5) 𝜋𝜋 + is
𝑍𝑍*minimum.
𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖] + 2 𝑋𝑋* 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠----------------- (1) The modification coefficients
methodologies are
The modification obtained
verified fromanother
through
coefficients obtainedthe twothe
from different
method methodologies
called
two different diameterare verif
methodologies ar
e Table 2, Table it is3 Calculation
observedof that modification for pressure
coefficient based angle of 20°,
on BTL the
through thedifference
ofanother method
gear called diameter
and pinion over the of the gear and pinion
recommended rollerover the recommended
through another method called diameter of the gear and pinion over the recomm
pin diameter.
𝑊𝑊$A = 𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐[(𝑘𝑘 − 0.5) 𝜋𝜋 + 𝑍𝑍A 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖] + 2 𝑋𝑋A 𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠------------------ (2)
calculated and standard
Addendum modification modules
Base
coefficient using is
Tangent Tip minimum.
length
diameter method Hence it pin is verified
diameter.
The that
The
measured the
measured
pin diameter. The value
and and
measured
value the
value
the calculated
and valueare
the calculated
calculated value are compared.
value The
The calculat
are compared.
compared. The c
where, values are obtained by using the equations (13) to (22) and tabulated in Table
in 5.
angle Using
and the theequations
module(11)of both
and (12)value
Measured
gear and
modification
Modification
pinion
coefficients are 20° and
values 3.5
are
calculated
(X1, X2) are
co-efficient
mm
obtained
values by using the equations (13) to (22) and tabulated
are obtained by using equations (13) to (22) and Table 5
𝑊𝑊$* - Actual base tangent length of gear over 𝑘𝑘* no. of teeth
ely.
obtainedGear
from the measured Tip diameter value. The measured Tip diameter values
𝑊𝑊 - Actual base tangent length of pinion over 𝑘𝑘 no. of teeth
tabulated in Table 5.
(across
$A
and calculated 9 teeth)
values of modification coefficients
𝑊𝑊$* A
=93.06 (X1, X 2) are given in Table 4
𝑋𝑋* = 0.9728 BJ BJ Equation 13
BCD EBCDFD
------------------------------------------------ (3) 𝑆𝑆# = 𝑆𝑆# +
= 2 𝑋𝑋
< #+𝑚𝑚 2 𝑋𝑋
tan#𝛼𝛼𝑚𝑚 tan 𝛼𝛼 ------------------------- (13
-----------------------
um modification
𝑚𝑚* = GHIJK
𝑑𝑑 Pinion
=𝑍𝑍 𝑚𝑚+(1
coefficient
(across
+ 𝑦𝑦 8
− 𝑋𝑋 )𝑚𝑚 𝑊𝑊 =81.76------------------ 𝑋𝑋 -----------------------
= 0.6509 (11)
<
&* * A $A A
teeth)
𝑚𝑚𝑖𝑖𝑖𝑖𝑖𝑖𝛼𝛼
BCL EBh
iCLFD
A = A =G HIJK + 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 +
kL
−
G
------------------------------------------------ (4)
-----------------------------------(16) BJ
𝑆𝑆< = < + 2 𝑋𝑋< 𝑚𝑚 tan 𝛼𝛼 Equation 14
------------------------- (14
ter finding
𝑑𝑑&A =𝑍𝑍 the values
A 𝑚𝑚+(1 + 𝑦𝑦 − 𝑋𝑋of
hjL
* )𝑚𝑚pressure angle
hL UL
and module,
---------------------- pitch (12)
------------------- circle diameters
Table 3: =Calculation
B mno of modification
EBKCDFD A coefficient based--------------------------------
on BTL.
ulated using
Addendum 𝑚𝑚𝑑𝑑*l*
Table
A
standard
= 𝑚𝑚𝑍𝑍
M *CDmno
4 Calculation
modification Nformula. The centre distance
of---------------------------------------------------
modification
KD coefficient
GHIJK using coefficient
Tip based
diameter is (5)equal
on Tip diameter
method
(17) to half
𝑖𝑖𝑖𝑖𝑖𝑖𝛼𝛼# = of
cd
ce?
the
+
f
𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 + ? −
c?
B
N?
-------------------------
Equation 15 (15
eferenceAssume diameters.
Using 𝑑𝑑lA𝑚𝑚 ==𝑚𝑚𝑍𝑍
L
O mno K
D
the Oequations
* mno K
From theTip
(11) and
calculations
diameter
(12) modification
it is coefficients
found that
------------------------------------------------------ (6)the
--------------------------------
(X1(18)
centre distance
, X2) are c f B Equation 16
L L 𝑖𝑖𝑖𝑖𝑖𝑖𝛼𝛼< = d + 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 + G − ------------------------- (16
mm. If itfrom
obtained is, less
the measured orqr more than the
Tip diameter measured
value. The measured value, there values
Tip diameter is a positive ceG or cG NG
𝑑𝑑l* = 𝑑𝑑* cos MU N --------------------------------- (19)
correction
and calculated onvalues either or Measured
of modification
D
both coefficients
thevaluegear(Xand pinion.
Modification
1, X2) are inInTable
co-efficient
given the4 case 𝑑𝑑g#of positive
= 𝑚𝑚𝑍𝑍
hij F
# hij F
Equation 17
------------------------- (17
?
n, gears are pulled + 𝑦𝑦MU−N𝑋𝑋apartA )𝑚𝑚 𝑑𝑑&*by an amount 1+X2' times
'𝑋𝑋*X----------------------- module. In hij this
, qr
𝑑𝑑lA
𝑑𝑑&* =𝑍𝑍 =Gear
* 𝑚𝑚+ (𝑑𝑑1A cos = 219.35 --------------------------------
------------------ = 0.9714 (20)(11) F
L
𝑑𝑑g< = 𝑚𝑚𝑍𝑍# Equation 18
------------------------- (18
higher𝑑𝑑&Aamount
=𝑍𝑍
𝑀𝑀&*A 𝑚𝑚+
Pinion
,
= (𝑑𝑑1l* ++of𝑦𝑦 𝑑𝑑−s backlash
𝑋𝑋* )𝑚𝑚 𝑑𝑑&A = 201.6usually----------------------
results. Therefore,
------------------- to
----------------------------------(21)
𝑋𝑋A = 0.7356 (12)minimize the
hij FG

, the gear Table

pairs 𝑑𝑑lA , are brought closer to an intermediate value (centre
𝑀𝑀&A 4=Calculation + 𝑑𝑑s of modification coefficient----------------------------------(22)
based on Tip diameter
𝑑𝑑g# = distance
,
𝑑𝑑# cos H I
lm
N?
Equation 19
------------------------- (19
ion coefficients,
Table 4: Calculation ‘y' to ofget a new
modification centre
coefficient distance.
based
Table 5 Values obtained for verification using Pin over diameter
on tip diameter.
, lm
Equation 20
Tip diameter
Validation of addendum modification co-efficient 𝑑𝑑g< = 𝑑𝑑< cos H I ------------------------- (20
NG
or the modified gear
The1 modification
2 pair,3Atheobtained
coefficients centre distance
3B from is equal
the twoDifference
different to the 𝑀𝑀
methodologies sum= of , pitch
𝑑𝑑g# + 𝑑𝑑o ------------------------- (21
Measured value Modification co-efficient L# Equation 21
dii of gear and pinion
are verified through another and value
method
Calculated the over
called sum pins of the centre distance modification
diameter of the gear and pinion over the
,
recommendedGear roller pin diameter. The measured value and 𝑋𝑋* the calculated value are 𝑀𝑀L< = 𝑑𝑑g< + 𝑑𝑑o -------------------------
Equation 22 (22
nt times
compared.
theThemodule.
minimize
Measured
the
calculated
value
The
backlash, the
Using
values
centre
𝑑𝑑&* = 219.35
gear pairs distance
are brought
Using
are obtained
coefficient
by usingcloser
= 0.9714 'y',
to an intermediate
the equations
working
(13) to (22)
pressure
value (center
w) and
andtabulated
the
distancesum of 5modification
inmodification
Table.
Pinion
coefficients,
Coefficients ‘y’
coefficients,
to get a(2)
Coefficients newandcenter
𝑋𝑋AX 1+X2 (theoretical value) are
(3A) distance.
(2) and (3B).
Table𝑑𝑑&A
3 = 201.6Table 4
= 0.7356 RESULTS AND DISCUSSION
d using𝑆𝑆For
equations [INSERT TABLE 5]
2 𝑋𝑋 (8)
𝑚𝑚 tanto (10)theascenter
per DIN 3960.
the
GO modified gear pair, distance is equal to the sum of pitch circle
Fromradii
Tableof 5,
gear
it can be seen that the sum of the differences DxG and
= +223.360
*Gear 𝛼𝛼223.864 223.845 -----------------------------------(13)
∆S*t = 0.504 ∆SAt = 0.485
and pinion
A and* the sum of the center distance modification coefficientResults
times the
andmodule. The
DxP areDiscussion
minimum in the case of Dx1G and Dx1P. Thus the profile modi-
o derive𝑆𝑆center
Validation the
Pinion
ofGOdistance
addendum coefficient
modification
207.610 ‘y,’ working
coefficient,
207.921
modification
A = A + 2 𝑋𝑋A 𝑚𝑚 tan 𝛼𝛼
pressure
208.452
co-efficient ∆S*uangle
different= 0.311(αw)∆and
methodologiesthe sum of modification
SAu = 0.842 are
-----------------------------------(14)
From the
available.
fication
table itcoefficients
can be seenobtained through
that the sum of thethe BTL method
differences are ∆closer
∆ and aretominimum
coefficients, X1+X2 (theoretical value) are calculated using equations (8) to (10) as per DIN qr qs
e the study
The3960. involves
modification
hi
remanufacturing
Sumcoefficients
of differencesobtained from
kD G
of the used
0.815 one, 1.327
two different it methodologies
is proposed
case ofthe to follow
and ∆
measured
∆q#r q#s . Thus the profile modification coefficients obtained through BT
value.
𝑖𝑖𝑖𝑖𝑖𝑖𝛼𝛼 = + 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 + − -----------------------------------(15)
hods which
are verified
To
*
Tablederive
5:
use
through the
hjD another
thepin
Values
measurement
modification
obtained
method
hD
coefficient,
for verification
of existing
UD called diameter
usingdifferent
pin over
of the gear component.
methodologies
diameter.
and pinionmethod overIn
are available.
the
arethis
Thecloser
gearstudy,
toand
But, since the
the pinion
measured
withvalue.
the above obtained modification coef-
Results
recommended and discussion
roller diameter. The measured value and the calculated value ficients
are are brought closer by, i.e.modification
0.1829 mm,coefficients
to achieve minimum
d compared.
base tangent
study The involveslength
calculated (BTL)are
remanufacturing
values and tip diameter
of used
obtained one,
by itusing have
is proposed
the tobeen used
follow(13)
equations the forand
Themethods
gear
to (22) finding
pinionuse
which the above obtained
with are brought closer
a used one, it is proposed to follow the methods that use the mea-by (𝑋𝑋 backlash
+ 𝑋𝑋 − of 0.03
𝑦𝑦) 𝑚𝑚, mm,
i.e. which
0.1829 mm is equal
to to
achieve DIN Class
minimum 5backlash
accuracyofstandard
0.03 mm which
ntsand
and pin
the
tabulated
surement over
measurement
From the diameter
in Table.table
of
of
it can
an5existing
be was
existing
seen used for
component.
that the
component.
sum
In verification.
In
of this
the study, measured
differences ∆ St
this study, measured base
base
and ∆ Su tangent
are # length
< (BTL)
value that is required for a high accuracy CNC machine tool gearbox
minimum
and tipindiameter
the casehave S*t and ∆
of ∆been . Thus
usedS*ufor thethe
finding profile modification
coefficients equaldiameter
and coefficients
pin over to DIN was
Classused
5 accuracy standard value that is required for high accuracy CNC
GO length (BTL) and tip diameter have been used for finding
tangent
obtained
𝑆𝑆*for through
+ 2 𝑋𝑋BTL
= verification.
* 𝑚𝑚 method
tan 𝛼𝛼 are closer to the measured value. machine tool
and
-----------------------------------(13) gearbox
maintaining andthe
maintaining the center
center distance distance
of gear pair.of gear pair.
A
the coefficients, and pin over diameter was used for verification.
GO gear
The and𝑚𝑚pinion Conclusion
coefficients are brought CONCLUSION
&T U 𝑆𝑆VU
A = + 2 𝑋𝑋A tan 𝛼𝛼 with above obtained modification
-----------------------------------(14)
= - closer
D
-L *N+ON𝑋𝑋A − 𝑦𝑦) 𝑚𝑚, i.e. 0.1829 mm
L A
by (𝑋𝑋
𝑦𝑦 = M - ? G -
-------------------------------------
to achieve minimum backlash of 0.03From
------------------------------------- From(8)
mm the approach
Equation 8 (8) of evaluating
the approach unknownunknown
of evaluating geometry of high accuracy
geometry gear
of high the followi
accu-
O A Jequal
which
𝑖𝑖𝑖𝑖𝑖𝑖𝛼𝛼is
hi < to DIN Class
kD 5Gaccuracy standard value that is required for high
* = h + 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 + h − U
conclusions can be drawn:
-----------------------------------(15)
accuracy CNC jD machine toolD gearbox
D and maintaining the centre distance of gear racy gear the following conclusions can be drawn:
CDEF A relation between module and pressure angle was established,
= cos pair.𝛼𝛼P = HIJK
E*
Z cos @# T GU X
^V?WVGO# Equation 9 (9)  
-------------------------------------
------------------------------------- (9)is applicable
) L[
V* A relation
• which between module
for bothand
thepressure
gear andangle was The
pinion. established which
different stan-is applic
\D ]\L
Conclusion both the gear and pinion.angles
The different standard value of pressure angles is ass
(YZ[FM @YZ[F)
Equation dard value of pressure is assumed and the corresponding
𝑋𝑋# + 𝑋𝑋< = (𝑍𝑍# + 𝑍𝑍< ) ------------------------------------ - 10 (10)
and the corresponding
(_`aK T E_`aK)
< \LZF module was obtained module
from thewas obtainedThe
relation. from the relation.
obtained valueThe obtained va
of the
+ 𝑋𝑋A = From the (𝑍𝑍* + 𝑍𝑍A ) ------------------------------------gear
approach of evaluating unknown geometry of high accuracy -- module
(10)and the standard value of module were compared. The actual value of
A b&`K
the following conclusions can be drawn: was ascertained where the difference is found to be minimum.
June 2018     43
Addendum Modification Coefficient Using the BTL Method • The method of finding addendum modification coefficient, using BTL method
 BTL

Figure 3: Gear data calculation steps.

44     gearsolutions.com
 dr2 – Root circle diameter of pinion
module and the standard value of the module were compared. The
actual value of the module was ascertained where the difference is Wk1 – Actual base tangent length of gear
found to be minimum. Wk2 – Actual base tangent length of pinion
The method of finding the addendum modification coefficient a – Standard center distance between the gear and pinion
using the BTL and tip diameter methods and verification using pin
aw – Modified center distance between the gear and pinion
over diameter is found to be useful for gear parameter evaluation
of an unknown gear. y – Center distance modification coefficient
The BTL method is observed to be better for finding the adden- dg – Measuring pin diameter
dum modification coefficient for the gear pair based on the minima S1 – Gear tooth thickness for the corrected gear
obtained between the calculated and measured values of pin over S2 – Gear tooth thickness for the corrected pinion
diameter.
dp – Distance between the pin for the even number of teeth
The amount by which the gear pair is to be brought closer to
obtain the desired backlash as per DIN class accuracy can be derived d'1 –Distance between the pin for the odd number of teeth
using the above methodology.  Ma – Diameter over pin
a1 – Pressure angle of the involute profile at the pin center for gear
REFERENCES
a2 – Pressure angle of the involute profile at the pin center for pinion
[ 1 ] Kumar, A.; Jain, P.K.; Pathak, P.M. (2014). Machine element reconstruc-
tion using integrated reverse engineering and rapid prototyping approach. DxG – Difference between the measured and calculated value of pin over diam-
Proceedings of the 26th All India Manufacturing Technology, Design and eter on gear
Research Conference, IIT Guwahati, Assam, India. December 12-14, 2014 DxP – Difference between the measured and calculated value of pin over diameter
123, 1-5.
on pinion
[ 2 ] Grimsley, P. (2003). Software solutions for unknown gear. Gear Solutions.
June 2003, 16-23.
[ 3 ] Innocenti, C. (2007). Simple techniques for measuring the base helix angle
ABOUT THE AUTHORS
of involute gears. In Proceedings of the 12th IFToMM World Congress,
Besançon, France, June 18-21, 2007, 406-412. Prasmit Kumar Nayak, A. Velayudham, and C. Chandrasekaran are
with the Combat Vehicles Research and Development Establishment
[ 4 ] Belarifi, F. and Bayraktar, E. Benamar, A. (2008). The reverse engineering to in Avadi, Chennai, India. Nayak can be reached at prasmit1@gmail.
optimise the dimensional conical spur gear by CAD. Journal of Achievements com, Velayudham at [email protected], and Chandrasekaran at
in Materials and Manufacturing Engineering. 31 (2), 429-433. [email protected].
[ 5 ] Schultz, C. D. (2010). Reverse Engineering. In proceedings of the AGMA
Fall Technical Meeting. AGMA Technical Paper 10FTM09. 9pp. Milwaukee,
Wisconsin.
[ 6 ] G. Gonzalez Rey, A. G. Toll and C. I.E.R. Gonzalez, A Procedure to deter-
mine the unknown geometry of external cylindrical gears, Gear Solutions,
Feb 2016.
[ 7 ] Jadhav, S. and Sandooja, A. (2012), “Analytical Approach to Gear Reverse
Engineering (Spur and Helical),” SAE Technical Paper 2012-01-0812,
2012.
[ 8 ] A. Alshennawy, (2014), A Reverse Engineering Technique for Reproducing
Spare Parts using Computer Vision System, International Journal of
Scientific and Engineering Research, Volume 5, Issue 10, October-2014.
[ 9 ] Charles D. Schultz (2010), Reverse Engineering, AGMA Technical Paper
10FTM09.

NOTATIONS
Z1 – Number teeth on gear
Z2 – Number teeth on pinion
m – Module of gear and pinion
X1 – Modification on gear
X2 – Modification on pinion
a – Pressure angle
aw – Working pressure angle
d1 – Pitch circle diameter of gear RUSSELL, Precision Gear Products
HOLBROOK &
STOCK : HOBS : HSS & CARBIDE
d2 – Pitch circle diameter of pinion STOCK : SHAPERS : Disc & Shank
db1 – Base circle diameter of gear HENDERSON, INC. STOCK : MASTER GEARS
RFQ on specials gear tools welcome
db2 – Base circle diameter of pinion 25 E Spring Valley Ave., Maywood, New Jersey 07607
P: 201-226-9000 F: 201-226-9004 E: [email protected] Diametral Pitch 12 and finer
d a1 – Tip circle diameter of gear CELEBRATING 100 YEARS IN BUSINESS STOCK AVAILABLE
d a2 – Tip circle diameter of pinion
dr1 – Root circle diameter of gear www.tru-volute.com
June 2018     45
 DRIVING GEAR
DEVELOPMENT

500CB’s closed-loop system corrects for blade

movement during automatic clamp screw
torqueing and provides ‘intelligent’ feedback
for more precise truing.

46     gearsolutions.com
Gleason technologies help SEW Eurodrive meet global
demand for compact, quiet, and very high-efficiency
spiral bevel gear units.
By UWE GAISER 

A
sk Chuck Chandler, plant manager at SEW the gearsets at Gleason.
Eurodrive USA in Lyman, South Carolina, about “We didn’t initially have the volumes or, frankly, the
the range of applications for the spiral bevel gear grinding expertise, to justify a grinding machine pur-
units produced there, and his response is sim- chase,” Chandler said. “Outsourcing to Gleason gave us
ple: the world. The ultra-modern 385,000-square-foot a chance to learn about the process and see firsthand
facility, winner of Plant Engineering Magazine’s Top how well the 280G performed, so when the time came,
Plant Award in 2007, is running three shifts a day, six we bought one right off the floor at IMTS 2014.”
days a week, and busting at the seams to keep pace with
record demand from SEW Eurodrive Assembly Centers PROVEN PHOENIX PERFORMANCE
around the world. But if you think these production Today, this 280G is helping meet the world’s growing
challenges keep Chandler up at night, guess again. appetite for SEW Eurodrive’s servo gear units and
“We’ve never been more productive or efficient,” he performing so well that Chandler and his team are
said. “And we have some of the latest Gleason technolo- looking at a second machine and more opportuni-
gies helping us get there. It’s a good problem to have.” ties to apply grinding, whether for noise reduction
or to squeeze more torque out of a smaller gearset.
GRINDING FOR MORE PRECISION The machine’s exceptional reliability has come as no
Ten Gleason Phoenix bevel gear cutting machines, surprise to Chandler, since the 280G is built on the
including four of Gleason’s latest generation of 280CX same platform as his tried-and-true Phoenix 280CX
machines, produce all of the spiral bevel gear sets used cutting machines. It also features an exception-
in SEW Eurodrive’s popular ally well-designed work area
K Series of right-angle gear for swarf containment and
units. The K Series is an indus- evacuation. This is critical
try workhorse, renowned for for ensuring fast, accurate
delivering 96 percent efficien- bevel gear grinding, as well
cy and very quiet, wear-free as helping to minimize the
performance across a 200 Nm time-consuming and expen-
to 50,000 Nm torque range. sive maintenance challenges
These gears are heat-treated of swarf accumulation and
and then lapped and tested on contamination.
Gleason HTL TurboLapper and Virtually all of the usual
HTT TurboTester machines. wires, piping, and even the
But with the introduction in door rails have been moved
2004 of a new family of servo out of the work area and put
gear units, designed for very behind guarding, so swarf
The 280G eliminates pipes, wiring, and clutter
high precision applications is easily contained and falls
from the work area so that swarf containment and
where positioning toler- evacuation is extremely efficient. Quick-change free for collection by the cool-
ances are often measured in coolant headers speed setup and ensure optimum ant chute positioned directly
microns, Chandler and his coolant delivery. below the work area. In addi-
team recognized that lapping tion, the 280G is equipped
these gears as a hard finishing process wasn’t going with an integrated dressing unit with a unique tele-
to be good enough. scoping design that enables it to extend into the work
“The spiral bevel gearsets in these servo gear units area for dressing, and then fully retract flush with
must be produced with very tight tolerances and oper- guarding during the grinding cycle.
ate backlash-free, so we opted to finish grind them,” But what Chandler also appreciates now is just how
Chandler said. “Plus, by grinding gears and pinions productive the 280G is.
independent of each other rather than having to lap “We’re producing 24 different gears and pinions
them as mated sets, we have the added flexibility of in the servo gear family, and once you set it up for a
finishing gears or pinions in the optimum lot sizes part for the first time, replicating that same part setup
and on demand.” downstream is very fast and easy,” Chandler said.
Early on, SEW Eurodrive relied on Gleason and its He attributes some of this setup speed to the color-
Phoenix 280G Bevel Gear Grinding Machines to grind coded sets of quick-change coolant headers that allow
June 2018     47
the operator to easily optimize the flow of Blade Inspection System to quickly and effi-
coolant for each part, critically important in ciently sharpen and inspect all the carbide
order to avoid surface defects and achieve stick blades used in these Gleason Pentac or
the desired surface finish and flank form older Gleason Tri-Ac face hobbing cutter sys-
accuracy. tems. But much of the operators’ time was
The machine is also equipped with a spent building, truing, and inspecting the
quick-change grinding wheel spindle design, cutter heads, a process that, according to
as well as a work spindle that allows conven- Chandler, took upwards of 90 minutes per
tional arbors to be installed to, and removed head and could result in costly blade mis-
from, the front of the machine. All of these alignments and blade chipping despite the
setup tasks are performed by the operator expertise of the technicians. So, it’s not sur-
without tools. Non-productive time is fur- prising that, 18 months ago, Chandler took
ther reduced through use of an automatic advantage of the opportunity to make his
stock divider, mounted in close proximity to tool room the first beta site for Gleason’s new
the work spindle, that operates simultane- 500CB Cutter Build Machine.
ously with wheel dressing. “It’s inevitable that building, truing and
Load/unload automation is easily integrated with the inspecting cutter heads manually will result
EASILY AUTOMATED 280G, further reducing non-productive time. in the occasional blade misalignment, but
FOR MORE EFFICIENCY even one is too many,” Chandler said. “This
As one would expect, SEW Eurodrive makes extensive use of automa- can cause a chipped blade downstream, and drastically reducing tool
tion. Robotic load/unload is used on 90 percent of the gear cutting life as a result. Now, with the Gleason 500CB, all of those manual
machines and was easy to integrate on the 280G. steps are performed automatically and with greater precision and
“Our studies show that manual load/unload is, at best, about 72 repeatability by the machine. A process that once took 1½ hours now
percent efficient, which means a machine will be waiting a lot,” can be done in 30 minutes or less, and we’re no longer worried about
Chandler said. “On the 280G, we use the robot to not only load and misalignments and chipping blades. Plus, we’ve freed up our tool
unload the machine, but also to hold the part for cleaning and pick room people so they can be productive while the 500CB is doing its
and place the part at laser etching and palletizing.” thing.”

AUTOMATING CUTTER BUILD LESS WORK, BETTER RESULTS

Perhaps the only productivity stone
left unturned at the Lyman plant, The new Gleason 500CB Cutter Build Inspection Machine is the first
until recently, was in the tool room, where
as many as 25 cutter sys- of its kind to fully automate most of
the critical steps in the cutter
tems are built every three-shift day to meet the needs of 12 bevel gear build and truing process. Its predecessor, the Gleason CB machine
cutting machines. True, tool room operators make good use of two has, for years, been a solid workhorse in tool rooms worldwide and
highly productive Gleason BPG Blade Grinding Machines and a GBX succeeded in lifting some of the burden from the operator’s shoulders

Ten Gleason Phoenix bevel gear cutting machines, including four of Gleason’s latest generation of 280CX machines, produce all of the spiral bevel gear sets used in SEW
Eurodrive’s popular K Series of right-angle gear units.

48     gearsolutions.com
SEW Eurodrive was the beta site for Gleason’s first 500CB machine. Today, the machine is reducing cutter build times from the 90 minutes needed previously
to less than 30 minutes.

The new Gleason 500CB Cutter Build process unfolds, the 500CB actually learns from the measurement
feedback it receives, and loosens, tightens, and measures blades again
Inspection Machine is the first of its as needed — just as the technician would do — until blades are trued
to their optimum radial and axial position down to ±2 microns if
kind to fully automate most of
the needed. It’s an adaptive process, too, with the 500CB learning from
every build to optimize future builds. Once the operator has loaded
critical steps in the cutter build and the cutter head, positioned the build carriage, and loaded the blades,

truing process. he’s free to perform other tasks while the 500CB completes the build,
truing, and inspection operations.
If the operator chooses to, he can view a screen on the machine’s
by automating a few of the critical steps in the build sequence. But CRT charting every blade’s position and runout in real time. And,
the 500CB goes much further than the original CB. at any point in the process, start to finish, the operator can use the
Now, after cutter build data is input, all the operator does is load intuitive operator interface with software “wizards” to guide him
the cutter head, position the build carriage, and load the blades into through every step of setup and operation.
their respective slots. Next step? Press GO and walk away, with 30 According to Chandler, the 500CB’s impressive functionality isn’t
minutes or so of time now available for other tasks. Now, all the limited to just a few cutter systems types or sizes either. It can be
other steps that have taken so much time and been so dependent easily applied to both newer Pentac cutter systems and the older Tri-
on the operator and his expertise are performed automatically by Ac cutter heads still in use, as well as the wide range of cutter head
the 500CB. Blades are positioned in their slots, clamp screws preci- diameters running on SEW Eurodrive’s cutting machines, from as
sion-torqued, and blade axial and radial position measured. As this small as 70 mm (2.75”) to as large as 533 mm (21”).  

ABOUT THE AUTHOR

Uwe Gaiser is director of Product Management, Bevel Gear Manufacturing Solutions, at the Gleason Corp. Learn more at www.gleason.com and
www.seweurodrive.com.

June 2018     49
COMPANY WOLVERINE BROACH CO. INC.
PROFILE

SERVICING
THE ENTIRE
PROCESS

A rack and pinion shaver broach tool.

(Courtesy: Wolverine Broach)

50     gearsolutions.com
Wolverine Broach Co. Inc. has developed
a reputation for craftsmanship, design,
engineering, and support services.
By KENNETH CARTER, Gear Solutions editor

B
roaching can be quite the competitive arena in many companies have tended to shy away from,”
the manufacturing world, so it’s imperative for Bernard Aude said. “Our primary industries are air-
a company to take those extra steps to bring craft and automotive, since the larger production vol-
customers to its door. umes go hand-in-hand with the broaching application.
At Wolverine Broach Co Inc., company President And we’ve also been at it for quite a while.”
Bernard J. Aude Jr. prides himself in that ability. Some of the products and services Wolverine
“We’re considered a small organization, which Broach offers include pot broaches, keyways, aircraft
allows us to fly under the radar and exceed our cus- broaches, steering rack broaches, quadrant broaches,
tomer’s expectations compared to our larger competi- hexagon tools, straight spline broaches, involute spline
tors,” he said. “The quality of our tool will sell itself, broaches, square and rectangular broaches, D and
yet due to the lack of broaching knowledge in the Double D broaches, and more.
industry, you also have to service the entire process.” That quality of service has made some of Wolverine’s
With their quality and customer-service ability, customers take extra notice.
Wolverine Broach has established itself as a critical “I’ve worked with Wolverine Broach through
and key supplier over the entire broaching industry. endless new programs and retool projects,” said one
customer. “I’ve come to realize that working with
RACK AND PINION LEADER Wolverine has proven to be one less variable to stress
Wolverine Broach has been a leader in the steering, over when starting up a new product component line.
or rack-and-pinion discipline, and has supplied prod- The level of quality and support they provide during
ucts to companies throughout and after is what most end users
the years that supply to General
Motors, Ford, Chrysler, ZF (TRW),
“With broaching, strive to obtain.”
Wolverine Broach’s excellence
and transplant companies that it’s becoming an was most recently recognized by
have invested in or relocated to Pratt & Whitney with an award
North America. unknown art, which for superior quality for the 2017
“We produce a vast majority
of the rack-and-pinion broaches is unfortunate calendar year. According to the
Audes, it is a difficult award to
in the North American market,”
Bernard Aude said. “It is the
because of how achieve in just four years.
“To accomplish this feat at the
strength in our ability to quickly competitive it Pratt & Whitney, Connecticut,
problem solve a tool design and location in such a limited time
offer product support that sets us can be to other is difficult to do,” Bernard Aude
apart from the competition.”
Part of what makes Wolverine processes.” said. “So, we have moved very
quickly into a position of tops in
so accomplished is the company’s quality.”
attention to detail, according to Matthew Aude, vice Of all the turbine disc broaching operations, Pratt
president of sales. & Whitney has one of the most stringent tool accep-
“First and foremost, we listen to our customer to tance procedures in the entire industry, according to
better understand what they are currently having con- the Audes.
cerns with, which allows us to react more efficiently “Working with Wolverine is a great experience,”
to provide a solution,” he said. “As Bernie previously said Jose Acosta with Pratt & Whitney. “Their focus
stated, we do have that flexibility as a smaller organi- on process improvement, cost reduction, and on-time
zation where we can re-appropriate capacity in order delivery, along with a great service, makes Wolverine
to meet a customer’s demand very quickly.” a good supplier to work with.”

PREFERRED SUPPLIER SATELLITE LOCATION

As witnessed in its market share in the rack-and-pinion Wolverine also has a satellite location in Alcoa,
broaches, Wolverine has become a preferred and Tennessee, that primarily serves the Southeastern
valued supplier at a number of additional end users. region and can quicken the turnaround for the com-
“It’s similar to a single source opportunity which pany’s services.
June 2018     51
A Blohm 412 CNC surface grinder. (Courtesy: Wolverine Broach)

“This site was established 20 years ago

with the idea that we were going to more
quickly respond to a target customer,”
Bernard Aude said. “That has set us apart.
We can turn tools around in a regrind state
in less than a week, and that’s door to door,
sometimes including coating. Give us a tool
one week; it’s going to be back to them the
next week.”
“It reduces their inventory or f loat
demands, so it reduces their costs,” Matthew
Aude added. “If a customer has a broach com-
pany that is servicing them from afar, those
tools are then transported via truck or even
air, which cripples lead time. So, localization
has a direct impact on inventory control
which is a key component in reducing their
tooling costs.”

46 YEARS OF SERVICE
After accumulating more than 25 years of
broaching experience, Bernard Aude Sr.
decided to start his own broach company. He A Blohm 408 CNC surface grinder. (Courtesy: Wolverine Broach)
created Wolverine Broach Co., Inc. in July of
1972. It moved into a new facility in Harrison Production & Engineering in 1982. With Division in Alcoa, Tennessee, was another
Township, Michigan, in 1981 and has been at this addition, Wolverine Broach was able to idea developed by Bernard Aude Jr. to meet
that address ever since. provide a full spectrum of broaching ser- specific demands.
Bernard Aude Jr. started working at vices from tool manufacturing to the pro- Those years of experience are what the
Wolverine Broach in 1972 after earning an duction broaching process. As mentioned Audes and their team use to meet their
engineering degree from the University previously, the establishment of the satel- customers’ needs head on. Wolverine is an
of Michigan. He also opened Wolverine lite facility, Wolverine Broach Co., Inc. S.E. American-owned company with three gen-
52     gearsolutions.com
Wolverine Broach receives the broach supplier award from Pratt & Whitney. From left: Matt Aude, Bernie Aude,
Jose Acosta, Dave Parent, and Ryan Kimball. (Courtesy: Wolverine Broach)

erations of the Aude family involved in its edge, so it helps the industry as a whole.
operations.
EYE ON THE FUTURE
TRAINING THE CUSTOMER As Wolverine Broach continues to provide
“With broaching, it’s becoming an unknown quality broaches to a myriad of industries,
art, which is unfortunate because of how Bernard Aude said it will explore additional
competitive it can be to other processes,” avenues as technology challenges the busi-
Matthew Aude said. “The incoming engi- ness, such as fully electric cars with reduced
neers in our industry won’t know what mechanical back up.
broaching is until they get to the plant, and “We are always trying to reinvent our-
it is assigned to them.” selves with long-term opportunities” he said.
In the past, seminars were often offered “We have invested a substantial amount of
at the IMTS and AGMA trade shows by the capital back into the company over the past
larger companies and machine builders three years and have an annual plan for the
to teach engineers about the advantages next five years, at a minimum, to expand
with broaching, but those seminars aren’t our vision.”
offered with the same frequency, according Even though there are CNC machines in
to Matthew Aude. the broach industry, broaching doesn’t nec-
“Our larger competitors no longer offer essarily get easier, according to Matthew
the instructional classes as ownership has Aude. And that’s why the skilled and experi-
transferred from domestic to foreign and pri- enced labor becomes important.
orities shift,” he said. “We’ve actually been “Unfortunately, it’s not as simple as push-
working with a number of end users to try ing a button and a finished broach tool is
and start re-teaching the young engineers then taken from the machine,” he said.
and operators what broaching is. This is The complexity in a broach still requires
essential for our long-term survival.” a high degree of skilled labor, even with the
Wolverine has been setting up preven- CNC capabilities.
tative maintenance and operator training “Most of our employees have been with us
seminars over the past 18 months with great for 25-plus years,” Matthew Aude said. “It’s an
success. The company has provided these older employee base, but by the same token,
seminars in hopes of enabling customers they’re very knowledgeable, dependable, and
and increasing the overall product knowl- they take pride in what they do.” 

MORE INFO wolverinebroach.com

June 2018     53
 PRODUCT NEW PRODUCTS, TRENDS, SERVICES & DEVELOPMENTS
SHOWCASE
lars and couplings can be machined from
alloy steels, stainless alloys, titanium, alumi-
num with anodizing in bright colors, brass,
bronze, Delrin®, and other materials.  Sizes
can range from 1/8” to 12” I.D. with dimen-
sional tolerances of less than 0.001” and less
than 0.001” T.I.R. concentricity, depending
upon configuration.  3-D models can be pro-
vided for proof-of-concept testing.
Stafford Accu-Clamp™ Shaft Collars fea-
ture an integral clamp on one side while leav-
ing the other flat and perpendicular within
0.001” TIR to permit mounting next to pre-
cision bearings, sprockets, and gears.  For
mounting components, Accu-Mount™ and
Accu-Flange™ collars have a centering hub
with predrilled and tapped holes on their
flat side and flange, respectively.
Providing strong, mar-free clamping
power, Stafford Accu-Clamp™ Shaft Collars
are available made from aluminum, steel,
and stainless steel in 0.5” to 2” I.D. sizes. 
A Precision one-piece sleeve coupling with
a rigid center clamp section and the Accu-
Clamp™ feature at each end is offered for a
distortion-free coupling with a more precise
fit and shaft-to shaft concentricity within
0.001” TIR.
Stafford Accu-Clamp™ Shaft Collars and
related components are priced according to
size and quantity.  Price quotations are avail-
able upon request and custom modifications
can be accommodated. 

MORE INFO www.staffordmfg.com

Stafford custom shaft collars and couplings can be manufactured to precise design requirements from a wide Nord Gear shows
range of materials in a variety of configurations. (Courtesy: Stafford Manufacturing Corp.)
high-speed manufacturing
Clamping shaft collars, component compatibility issues are avail-
able. Stafford custom shaft collars and
at EXPO PACK 2018
rigid couplings permit couplings can be manufactured to precise Nearly 100 separate conveyors, in-line

precision alignment design requirements from a wide range of

materials in a variety of configurations with
CT-scan screening machines, multiple infeed
lines, four-way sorters, high-speed diverters,
special bore features such as hex, square, or spiral power curves and tray sorters — these
Stafford Manufacturing Corp. of Wilmington, round shapes and keyways including hing- are just some of the components powered
Massachusetts, has introduced a full line of es and threads.  Exterior modifications can by Nord Drivesystems motors and drives in
shaft collars, mounting collars, and sleeve include flats, slots, knurls, laser etching, high-speed material handling, package sort-
couplings that provide highly accurate work- tapped through-holes, flanges, cams, target ing and luggage handling operations.
ing surfaces and mar-free clamping. inserts, levers, and related parts to meet NORD is accelerating the speed of manu-
Custom-designed shaft collars and rigid OEM specifications. facturing and material handling as it deliv-
couplings that solve specific mechanical Supplied in prototype through produc- ers integrated power technologies to help
drive or packaging system and conveyor tion quantities, Stafford custom shaft col- the world’s largest manufacturers, online
54     gearsolutions.com
retailers, warehouses, and airports produce most cost-effective and hassle-free modular speed feedback via incremental encoder on
and move products faster, with less energy gearboxes available. the motor generates the highest possible
and more control. NORDBLOC.1 Helical In-Line Gear Units: acceleration and guarantees full motor
Customization saves time and money. A robust and cost effective in-line gear unit, torque throughout the entire speed range.
Nord’s modular, quick-connect drive systems the NORDBLOC.1 is ideal for a wide range Nord customizes products to provide the
can be equipped with a variety of common of demanding applications, from the high- specific features and functionality custom-
industrial Ethernet communication proto- speed conveying power needed in warehouse ers need.
col modules for remote monitoring and con- and package handling systems to pumping LogiDrive integrated solution: Nord’s
trol of individual drive units. Plus, Nord can and mixing food products. LogiDrive Solution combines the highly effi-
supply the units configured and supplied IE4 Permanent Magnetic Synchronous cient gearbox, the permanent magnet IE4
with required plug connectors for power, Motors: Like the gearboxes and drives used motor, and the versatile NORDAC LINK VFD.
photo eyes, sensors, and standard field bus with new international airport baggage- With this combination, users can achieve
systems to allow for easy installation. handling systems, Nord’s IE4 Permanent greater energy efficiency while greatly
The result: Nord delivers money-saving Magnetic Synchronous Motors and VFDs reducing the number of product combina-
solutions for tough environments. The high- can be pre-configured and delivered with
efficiency drive equipment and integrated customer-specified power connectors, and
technology reduce installation time and cost photo eye, sensor, and high-speed Ethernet
of operation. Plus, Nord’s high-quality equip- IP plugs needed for easy daisy-chain instal-
ment and customer support increase uptime lation. Because the motor offers best-in-class
and peace of mind. power density, with energy efficient opera-
At EXPO PACK 2018, Nord experts were on tion even at partial loads and reduced speeds,
hand to discuss integrated drive equipment it provides extremely low total cost of owner-
needs, including: ship and predictable load handling.
92.1 Helical-Bevel Gearbox: Nord’s 92.1 NOR DAC L I N K ( SK 250E Var iable
two-stage helical bevel reducer boasts up to Frequency Drive): This is another big piece
97 percent gear efficiency. The design using of the conveying system integration. The
finite element modeling technology with NORDAC LINK VFD family offers flexible
oversized output bearings and extremely drive capabilities for virtually any applica- The Sandvik CoroChuck 935 delivers fast, rigid, and
accurate construction means extended ser- tion and supports decentralized installa- secure clamping. (Courtesy: Sandvik Coromant)
vice life, even under high radial loads. Plus, tions. NORDAC LINK installation is fast and
with flexible mounting and shaft designs, simple, as is service. Integrated brake man- tions for an entire system. This solution is
product installation is fast. It’s one of the agement assures wear-free actuation. Direct available with power ratings between 1.5
and 7.5 HP and available for 50 Hz and 60 Hz
power systems. Nord’s solution is modular
and each of the components can be serviced
separately, thereby reducing costs, reducing
required variants, minimizing spare part
inventory, and increasing uptime.

MORE INFO www.nord.com

Hydraulic chuck
for turning offers
market-leading security
Cutting tool and tooling system specialist
Sandvik Coromant has introduced a high-
precision hydraulic chuck for turning opera-
tions that offers the market’s best pull-out
security. CoroChuck® 935 has been designed
to deliver fast, rigid, and secure clamping,
time after time.
With clamping security assured, machine
shops can confidently perform demanding
turning operations, including those with
long overhangs. In fact, CoroChuck® 935
ensures a clamping length of four times the
bar diameter. Developed for use on lathes,
Nord’s Nordac Link is shown controlling a 92.1 two-stage helical gearbox with IE4 synchronous motor, one of turning centers and multi-task turn-mill
Nord’s low-maintenance, high-efficiency drive technology solutions. machines, the new hydraulic chuck covers
Xxxxxxxx 201X     55
PRODUCT
SHOWCASE

most common machine interfaces. damping performance.” and improved insert life.
“The design principal behind the high Further benefits of the new chuck CoroChuck® 935 is available in 20 and
level of security offered by CoroChuck 935 include the use of EasyFix™ sleeves to pro- 25 mm bore sizes (¾ and 1 inch) to suit
is based on fulcrum technology,” said Åke vide the correct center height and help Coromant Capto®, HSK-A/C/T, cylindrical
Axner, global product manager – machine reduce set-up time. EasyFix™ sleeves are a shank, and VDI machine interfaces. Imperial
integration at Sandvik Coromant. “A thin, solution for cylindrical boring bars that sees sizes are available in Coromant Capto and
brazed membrane offers an optimized a spring plunger mounted in the sleeve click cylindrical shank interfaces.
clamping function, whereby expansion cre- into a groove on the bar to guarantee the
ates two distinct clamping points on each correct center height. The metallic sealing MORE INFO www.sandvik.coromant.com
side (fulcrums). The concept ensures the also offers good performance in applications
clamping force repeats for every use, provid- that require high pressure coolant. Moreover,
ing the best possible pull-out resistance and EasyFix™ facilitates excellent cutting action

The
Power
of One2 United Grinding’s new Ewag Profile Line was designed
to enhance production efficiency. (Courtesy: United
Grinding)
Your Objective:
One face in perfect alignment with another. For infinity.
United Grinding
transforms insert
grinding with Profile Line
United Grinding has unveiled its new Ewag
Profile Line, an indexable carbide insert
grinding solution. Developed in a partner-
ship between Ewag AG and sister company
No problems. No distress. No delays. Walter Maschinenbau GmbH, the Profile
That’s the same objective you have for choosing your gear producer. Line serves as an extremely efficient grind-
Circle Gear’s objective is to engage with every customer’s objectives. ing center for the advanced processing of
highly complex interchangeable insert
 One to 1000 gears
geometries and interfaces.
 Customer designed or reverse engineered The Profile Line enhances production effi-
 Gearbox repair, rebuild or redesign ciency with innovative technology such as an
intelligent, integrated six-station changer
 OEM or end-users
for grinding wheel sets with a coolant sup-
 ISO 9001:2015 Certified ply manifold that selects the optimal wheel
to ensure the maximum possible machin-
ing volume for sintered insert blanks. The
1501 S. 55th Court, Cicero, IL 60804
(800) 637-9335
machine integrates both Ewag ProGrind and
(708) 652-1000 / Fax: (708) 652-1100
Walter Helitronic Tool Studio into its FANUC
[email protected] control unit to further expand the range of
www.circlegear.com applications and improve insert geometries.
For unattended, lights-out operations, the
Spiral and Straight Bevel Gears (Cut, Ground or Lapped) • Spur Gears • Helical Gears • Profile Line comes equipped with an inte-
Long Shafts • Herringbone Gears • Involute and Straight Sided Splines • Internal Gears • grated six-axis FANUC robot that can easily
Worm and Worm Gears • Racks • Sprockets • ISO Certified
accommodate customer-specific pallets. A
Partnering with QualityReducer to provide high-resolution CCD-HD vision system is also
Gearbox repair, rebuilding and reverse-engineering. available for loading grid pallets using mag-
netic grippers. Cleaning, re-clamping and cen-
56     gearsolutions.com
tering stations can be integrated and adapted In addition to the GH-18 model, other
to the customer-specific product range. hydraulic and pneumatic versions of the
FlexArm are available to suit varied tapping
MORE INFO www.grinding.com requirements. Engineers are available to dis-
cuss unique project parameters and offer
solutions based on decades of experience.
FlexArm to feature A 30-day free trial period allows FlexArm

all-in-one hydraulic
products to be proven in-plant under actual
production conditions. The company stocks
tapping packages at IMTS an extensive array of tap holders and repair
parts in its Wapakoneta, Ohio, factory, for
FlexArm’s mobile tapping package allows machining
At IMTS September 10-15 in Chicago, FlexArm centers to do what they do best – milling, drilling, and fast shipment, often same day.
Inc. will feature a mobile tapping package boring. (Courtesy: FlexArm) FlexArm, headquartered in Wapakoneta,
that yields mobility, productivity, and effi- has been manufacturing tapping arms, die
ciency by allowing operators to tap holes ping arms are an ideal alternative to tapping grinding arms, torque arms, assembly and
offline while the machining center works on holes manually or via CNC. part manipulators, and more, since 1984.
the next part. FlexArm will occupy booths FlexArm allows machining centers to do Hydraulic and pneumatic tapping arms
#432115 and #236430. This comprehensive what they do best — milling, drilling, and bor- are available with guaranteed precision
package includes the FlexArm GH-18 tap- ing. When operators load a machining cen- and dependability. Hydraulic models have
ping arm with a tap capacity of #6 to 5/8”, a ter and start its cycle, they can use that cycle a tapping capacity up to 2 inches. It stocks
reach from 17-72 inches, variable speed from time to tap previously machined parts with an extensive array of tap holders and repair
100-420 RPM, 360-degree movement, and a the FlexArm — yielding more productivity parts for fast shipment – often same day.
semi-automatic tap lubricator. Additionally, per shift. Tap breakage rates are significantly All arms and systems include a 3-year war-
with a caster cart, power pack, tap stand, and reduced with the FlexArm due to its purpose- ranty. All motors and units are repaired
five tap holders, this hydraulic tool can be centered approach. With a tap breakage rate by FlexArm technicians in-house to speed
used wherever there is 110V available – with of 1 per 3,000 holes, versus 1 per 300 holes on turnaround times.  
no air needed. With fast set-up times and sig- a CNC, FlexArm tapping arms can significant-
nificantly reduced tap breakage, FlexArm tap- ly reduce set-up time, cost, and scrap rates. MORE INFO www.flexarminc.com

GEARING AHEAD TO MEET INDUSTRY'S

DEMAND FOR PRECISION
– SERVING –
[email protected] | [email protected] | (203) 775-4877
Aircraft • Aerospace • Actuation
ISO Certified / ITAR Registered / Trace Certified Instrumentation • Optic
Robotics • Radar • Medical
Marine • Defense • Experimental
Prototype • Production
Hi-Performance Automotive

Precision Gear Products (up to AGMA Q14):

Spur Gears, Helical Gears, Worm Gears, Anti-Backlash Gears, Cluster Gears, Clutch Gears,
Face Gears, Planetary Gears, Gear Assemblies, Gear Boxes, Bevel Gears, Miter Gears,
Metric Gears, Internal Gears, Idler Gears, Gear Rack & Pinion, Worms, Wormshafts,
Splines, Spline Shafts, Serrated Shafts.

CNC Thread Grinding

STD Precision Gear & Instrument, Inc.
318 Manley St. • W. Bridgewater, MA 02379
(888) STD-GEAR or (508) 580-0035
Nordex.com Fax (888) FAX-4STD or (508) 580-0071
E-mail [email protected] • Web site: www.stdgear.com

Xxxxxxxx 201X     57
  

MARKET KORO for Quality

 
 

PLACE
Hob Sharpening Service
 Quick Turnaround 2 Day Service  
 Spur Shaper Cutter Sharpening · Custom gear racks in AMERICAN and
 HSS & Carbide Hob with center hole   METRIC standards, STRAIGHT and
HELICAL, VARIOUS materials, FINE and
and straight flutes COARSE pitch (254 D.P. – 0.5 D.P.; 0.10
Contact Gear Solutions  Thin Film Coatings  
Module – 50 Module); hard-cut (up to
60 Rc) and soft-cut (up to 40 Rc); 32”
at 800-366-2185 to  Length up to 7 inches face width; Up to 82” lengths – longer
lengths through resetting

feature your business   · Custom gears in AMERICAN and

METRIC standards (3 D.P. – 72 D.P., 10”
 Diameter up Diameter)
in the Marketplace! to 5 Inches
 
· Precision Quality up to AGMA 12
· Prototype & Production quantities
 Precise rake · Breakdown Service Available
and spacing guaranteed · Reverse Engineering
· Unique Tooth Configurations
to AGMA standards   · Heat Treating
 RUSH SERVICE AVAILABLE · Complete CNC Machining

Koro Sharpening Service

9530 85th Ave North  
Maple Grove, MN 55369
763-425-5247
[email protected]  

 
Achieving Increased Profits
  and Response Times
As a leading global technology
  provider, this customer decided to
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  new location so they could
continue to grow and advance.
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421 SE Bailey Road • Lee's Summit, MO 64081

go.IpsenUSA.com/Customer-Stories

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303-447-1130  solaratm.com
www.kapp-niles.com Philadelphia Los Angeles
1.866.HOB.TOOL [email protected]
Pittsburgh South Carolina
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58     gearsolutions.com
072017_KappAd_NinthPage.indd 1 6/22/2017 3:39:30 PM
ADVERTISER UNITE-A-MATIC
TM

INDEX TRUE DIMENSION GEAR INSPECTION

CONTENTS PAGE NO.

ALD Thermal Treatment Inc.............................................................. 11

All Metals & Forge Group.................................................................. 53 OD / ID INSPECTION  DATA COLLECTION  CUSTOM TOOLING  MITUTOYO DISTRIBUTOR

United Tool Supply

American Precision Gear Co.............................................................. 59
CUSTOM FIXTURES
& GAUGES
Circle Gear & Machine Co Inc........................................................... 56 AVAILABLE

EMAG............................................................................................... 9

Engineered Tools Corporation............................................................ 16

Evonik Oil Additives USA.................................................................IBC

Gleason............................................................................................. 2
1973 45th
AN NI VE RSARY
2018

Hobsource Inc................................................................................. 58

Innovative Rack & Gear.................................................................... 58

Ipsen........................................................................................ IFC, 58 www.unite-a-matic.com

KAPP Technologies..................................................................... 21, 58

KISSsoft USA LLC........................................................................... 13

Koro Sharpening Service................................................................... 58

Lawler Gear Corporation.................................................................... 58 WWW.AMGEAR.COM

McInnes Rolled Rings....................................................................... 14

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

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

NORDEX.......................................................................................... 57

Penta Gear Metrology LLC................................................................ 25

Russell Holbrook & Henderson Inc.................................................... 45 CONTROLS

Solar Atmospheres........................................................................... 58

Southern Gear & Machine................................................................. 15

STD Precision Gear & Instrument Inc................................................ 57 MEDICAL DEVICES

Stor-Loc.................................................................................... 29, 58
CUSTOM PRECISION GEARS
The Broach Masters Inc...................................................................... 4 ISO2015, AS9100, DDTC

Toolink Engineering Inc...................................................................... 1 [email protected]

FOSTER CITY, CA
United Tool Supply........................................................................... 59 800-554-3150
Wickert USA.................................................................................... 13

June 2018     59
 Q& A CURTIS DICK
DIREC TOR OF QUALIT Y   
RIVERSIDE SPLINE AND GEAR INC.
INTERVIEW WITH AN
INDUSTRY INSIDER

“We consider ourselves North America’s job shop. That’s kind of

our theme. When we say we do quick turnaround, we mean it.”
Tell us about Riverside Spline and Gear Inc.’s place in the gear and they have onboard checking. These Class 14 (DIN 3) machines
manufacturing industry? run 23 hours a day. We service many industries with between two-
We consider ourselves the industry leader in the job shop arena. We and five-day turnaround on gear grinding only. Currently, about
are not afraid of large quantities and do them frequently, but we 35 percent of our work is gear grind only for other gear companies.
shine well in the one-off job shop arena. We consider ourselves North So, we have become an extension to their gear grinding capabilities
America’s job shop. That’s kind of our theme. We have an average lot for meeting their customers’ needs. We appreciate their trust in our
size of five or less, and that’s uncommon for most gear companies. gear grinding capabilities.
People are moving more toward mass production of gearing. And it’s
hard to find someone who has competitive pricing, is high quality, What are some of Riverside’s proudest moments?
on time, short deliveries in the one-off arena. We are that company. Back in 2013, we had our 50th anniversary. We’ve come a long way
When we say we do quick turnaround, we mean it. We have our from splining parts for the automotive machinery business and have
own inhouse bar stock, so if you give us an emergency order in the stayed true to our core values in being a leader in the job shop arena.
morning, we can have a piece cut off, turned, gear cut, and off to
heat treat that evening. That’s uncommon. Where do you see Riverside in the next 10 to 20 years and its
place in the gear industry?
What achievements have you recently accomplished? Our future is to grow. We have continuing plans for machinery,
The first and most important at this point is our commitment to manpower, systems, and brick-and-mortar. And we have the space
quality. We’ve achieved the requirements of ISO 9001:2015. And to make that happen.
this basically assures our customers that we have a commitment to We strive to continue to be our customers’ first choice. Our cus-
quality, maintaining a quality management system, and a business tomers tend to come to us first due to our quick quotes, and shorter
management system that is driven from the top down supported lead times, quality, and competitive prices.
by Aaron Forest, our president, CEO, and owner. Aaron is involved, It’s easier said than done to be a first choice, of course. We realize
daily, in the quoting process, operations, and quality functions. it takes a lot of continued commitment, not only in machinery, but
Corrective actions and the understanding of where we can improve in the training of our people. We have a lot of cross training. In the
are of utmost interest to Aaron. industry today, it is very difficult to find qualified personnel. We
often find that home growing is one of the best ways to increase
What equipment have you added to better assist customers’ and improve our staff. We find people with good attitude and apti-
needs? tude, and we grow them in the areas where they excel, and then
We’ve added six machines in the past five months. We are adding we stretch them into other areas where they can continue their
two more ID grinders this week and another cut-off saw in a few learning process. This enhances their experience and allows them
weeks. This changes pretty much on a monthly basis right now. Our to grow while contributing to the overall knowledge base of the
business is booming. We are adding machinery and people in order company. Cross training presents us with the opportunity to move
to meet our commitments to our customers. The largest machine manpower to the work instead of having the work back up in one
we’ve added is a Höfler 1500L gear grinder. This Höfler has a 59-inch department. We have a great longevity with our staff. This is greatly
diameter capacity, a 59-inch stroke, and can grind a shaft up to 99 important for our future.
inches long. We have added a Toshiba VTL and ID grinding to create We intend to grow the business in four ways:
the blanks large enough to accommodate this machine. Our whole Gaining market share with our current customers.
company is focused on our gear grinding. All the machinery that Adding to our ever-growing customer base.
we have in the shop is there to support making a gear blank that is Adding machinery and human resources as needed to meet
worthy of going on those machines. demands.
Continue to look for adding products and services to the busi-
Tell us about Riverside’s quick turnaround grinding service. ness as we see the opportunities to service our customers better.
Back in 2006, we broke ground on a new gear grinding center. We In short, we have had a tradition of quality since 1963. We intend
used to have old Reishauer grinders. And our customer base was to continue this tradition and our tradition of shorter lead times
talking about larger gearing and different kinds of gearing that and competitive pricing to meet our customers’ product and ser-
needed more modifications. We realized that we needed to keep it vice needs. 
in-house because we couldn’t find somebody out there to do that
for us. So, we purchased our first Höfler grinder. It was a Rapid 900.
Twelve years later, we have five Höfler grinders ranging from 400mm
MORE INFO www.splineandgear.com
to 1,500mm. They’re all equipped with Siemens 850D controllers,
60     gearsolutions.com
 Our Technologies, Your Tomorrow

The Advantage
of Supreme
Productivity

The Game-Changing Mitsubishi GE Series

CNC Gear Hobbing Machines.
A quick glance at Mitsubishi’s GE Series Gear hobbing machine doesn’t
reveal the truth behind it’s real power. However, when you evaluate the
output the full picture is dramatic and clear. With an all new, utlra-efficient
dry cutting design, the GE series machines produce gears up to 50% faster
than previous technologies—with all the precision your specifications
demand. This kind of boost in productivity is sure to help you be more
competitive in the marketplace and pump up your profits. Experience
GE20A
GEseries
the world-class performance of the GE series hobbing machines at
www.mitsubishigearcenter.com or contact sales at 248-669-6136.

N-237036