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T E e H N 0 L O G Y- - ---- - - --- - - - -

T H E J O U R N A L O F G E A R M A N U F A C T U R I N GSEPTEMBER I OCTOBER 1991

SPC IN G EAR H OBB IN G & SHAP INGF ULL -LO A D T ES TIN G O F LA RG E G .E AR B OX ES

BAS IC G EAR G ENERAT I,O N - DES IG NING THE TEETH

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Our cover photo courtesy ofSumitomo Macltinery Corp,of America, Chesapeake, VA.

- -CO'NTENTSSEPTE;\IBER / OCTOBEI{, 1991

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FEATURESS P C A c e , e p t a n c e o l l G e a r I H o b b i n g & S h a : p i n g M a c h i n e sBy Bl"ian Cl.uffAmerican Pfauter, Ltd . Loves Park. IL 2 6 ,I F u U ~ L o a d T e s t i n g ' o f L a r g ; e , G e a r b o x e s . . .By R.B. FrostUniversity of ew South WalesT.R. CrossJohn Welsh ~y LId Melbourne, Australia 3 5

SPECIAL FEATURESI G e a r F u n d a m e n t a l s : I B a s i e : G , e a r G e n e ra t i o n ~ D e s i g n i n g l l b e T e e d JBy R'ob,ert Moderow]TW. Illinois Tools, Lincolnwood. IL 4 0

DEPARTMENTSA G : M A I G : e ' a r E x p o ' 9 11 _Trade show and technical conference in Detroit 8' E x h i b i t o r ' s I i n d e xAdvertisers exhibiting at.Gear Expo 91 8V i e w p o i n t . _Our readers respond " 1 0P u b l is h e r ' s P , a g e .AOMA Gear Expo 9 l . 1 3A d v e r t j : s e r I i n d e xFind the products and services you need 1 6S h O i P F I 'o o : r . : S l in g l le F l a n ! k T e s t i n g ; H . .P . C a p a c i ! t yBy Robert E. Smith.R 0 IJ e r t E r r i c II e It 0 " 1 ' 1M a n a 'g e m e n t M a t t e r s : T a m : i n g t h e A u t o c r a : t i , e B o s sBy C .. Raymond Rogers,K ep ner- T fe gO e, 1 m:. P rin ceto n. N J 5 1C a l ! e n d a rEvents of inte re st ".. 6 0 1C l a s s i l , j e d s ,Products. services, and informarion you can use 6 2

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We've IPut it alii together:S:piral Beve'l Gear Appll'cationsKN :C 40 /60 f U i l l y CN C con tro lle d Genera to rs A MK IL arge G ear G enerators WN :C - 80 G r lind 'er C N C Inspection E quipm ent Quench P ressesWorm and Rotor Grinding Applications H N C S eries of C N C contro lled G rinders C N C Iinspection S ystem s

Para lle l Ax i s 'G ea r .App llca tions,. . C I N ! Cc on tro lle d 'g ea r I ns pe ctio n S y stems S 'N C S eries of C N C H ob S harpeners.. G e ar C u tting T ool In spe ction S yst,ems lH 'urth P roduct line: C N C S havers, H ard& F in e F in ish ers, S h av in gl C u tte r G r in de rsand Debu rr ing/Cham fe r, ing l Equ ipment

Puts iit a.11't:ogetlherwithl exciliin'g, ne'wp,rod'ucls, 110keeplyou com,pe't'itlive!'Gearmak ers w orld :w id e fa ce cu stome r d eman ds fo r h ig :h est q ua liity a nd o n- .tim e d eH v ery a tfie rce ly competttive p rice s. M ee tin g th ese d eman ds re qu ire sg rea te r fle x ib illity ." p roduc tiv ity and the ' ab ility to in teg ra te new technology .R e c ogniz in g y ou r u ltima te 'g oa ls - c us tomer s atis fa ctio n and I P fo ,fita bility -K liing :e lnbergl gl'oball te chnology is r ead :y w i:t:hthe most advanced CN C Sp i ra lB evel G ear G enerators and G rinders, and the m ost com plete line of C N CGear C h ec ke rs a va ila ble .. . a nyw he re .

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,,T h e KN :C ~ 4 0/6 0 'G e a r G e n era t,o rsT hese new , fu illy C N C , 8 axis g:ear generators produceS p ira l B e vell G e ars up , to .24" 0.0. P ,er f,ec tfor smal l!batch or lnterrnediate levell procuction runs, the KN GS eries 'generates S pira l B evel G e ars of any geom etryb y co ntinu ou s or siln gle in dexin g op era tio n. I ts pro grams to ra ge ca pa city fo r 250 differem workpteces andunlim ited storage capacity w ith a ID N C in te r face, makesit the m ost flexib le gear generator you ca n buy.

The WNC~80' 'Gear GrinderW ith leading edge technology, the W N C -S O becom esthe universal S pira l B evel G e ar ,grinder for any geargeometry . P e rfe ct fo r , gro und g ea r qua lity a pp lic atio nsup to 31.5" 0.0., the 'Qir,inde:r,off,ers Qireat versatili ty,.short set-ups and s uperio r a cc ura cy .

T he P N C S eries G ear C hec!k 'e :rsC ompact, new C N O controlled gear checkers providefui ll yau tomati c rneasur inq ot gears up t o . 80" 0.0. Fas toperation, high accuracy excellent documentation anda w ide variety of softw are m odules, term the perfectg ea r c he ck in g pac !k age.

F or th e late st in form atio n on K lin ge ln be rg system s th ats atisfy cu stome r d eman ds, fo r ln cre as ed p ro du ctlvltya nd p ro fita bility, co nta ct o ur re pre se nta tive . O r , w rite t o .KHnge ln be rg G e a r T e ch no lo gy, I nc .,15200 IFo l tz Industr !ia !1P arkway, S t rongsv il le , OH 44136.Phone: 216/57.2-2100.. ; F A X : 2116/ 572 -0985 . .@KLI~GELNBERO

- ...Puts It all together..see us AT

Booth #101C IR C LE A -4 on R E AD E R ,R E PI.:V C A RD

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. . . . . .Close d imens iona lG ( # F ! ' r Heat Treat in g:to .001"withGleaso.n #537 and #36 presseslMetaUurgical, Inc.g OO E a st H e nn ep in A v en ueMinneapolis, MN 55414( 612 ) 3 78-1500 'F a x 1 (612 )378-0462

C fRC l I EA 5 , on R EA DE R :RE Pl Y C AR D

A D IVIS IO N O FTPSThermo Process Systems Inc.

C H EC K T H E B EF E A T U R E S :,/ Accuracy- All grindingoperauons completed in asingle step., / Rapid Setup or Changeover-Bodies to blades, roughing tofinishing, other d'ameters.

,/ Full Probing Capabilities -For both part and wheellocation.rICBN Wheel- For bettersurface integrity and finish,longer tool li fe.

lihese features result hi ullpr,ecede.llted productivity.CON T.A CT U S FOR FUL L D ET AIL S

.ELK RAPilDSENGINEEFlINGSubsidiary of Star Cutter Company210 Industr ial Park Drive. P.O. Box 728 Elk Rapids, Mil 49629Phone 616/26456'611 '. Fax '616/2645663

VISIT US IN BOOTH 201 AT AGMA EXPO '91C IR CL E A -6,on IR EA DE R R EP LY C A'R O

6 1 (lEAR TECHNOLOGY

I GEAR TECHNOLOGYEDITOR!. \ I

Publisher & Editor-in-ChiefMichael Gol'dstein

Associate Publisher & Managing EditorPeg Short

Sen ior Editor - ancy BartelsPublishing Assistant Kell i R. Hopkins

Technical EditorsRobert ErricheUoWilliam L Janninck

Don McVittieRober t E. Smith

,\RTArt Director Jean Sykes

Art Director Jennlrer Goland.\D\'ERTISIi\'(;

Sales Manager Patrtela flamSales Coordinator Mary Michelson

R,\;-":LULL PllBUSllINC ST\FFPresident Michael Goldstein

Vice President Richard Goldsteln

Vice President /General Manager Peg ShortController Patrick Nasb

Accounting laura KlnnaneAdm inistrative Coordinator

Deborah DonlglanAn Consultant Marsha Goldstein

RA;\'D.\LL PliBUSIIli\'(;, [;\;C.

1425 Lunt AvenueP.O. Box [426E]k:Grove Village, IL 60007(708) 437-6604\'OL. S, xo. ~

CEAR i fE CHNOLOGV . j J' ll i: J u ocm al o f G e ii l" [ \. 1' jj nu r ll tt ut ln iL t IS : 5N0143~58) IS published b!mooUd)' b)' RI!JKII!.II Pklbh~hllt&. tac.. 1-42' Lun~Avc'nlit. P.o. B oK. 1 42 0 . E lk G ro v e V i ll il -g e. I L ,&KX}1 SubllcrlpUoo !lite!. lire:$40.00 ie t he u . .S. ; ' s'SO.OOlnC.IIu ! " :i d t i, . sS1i ,OOl lul l omerecenu les . SC\ .. .nd"ClA.' l ~pos~e paid a l A1"!ing~OfIH.,-i&-.II!'i. fL . ~ndIt I ! dd l ll oo; g l nmmng o ff ic e. R 1 I' K I3 ~ lPubhsh~J.1gmakes every .effon: til ensure Ih;u the processes ~I;ribi !.d If!GEA.Rif,.ClINOLOOY con fo rm to sound cl'l811ll!e."n!l8~\~r;,. Nei~ il'!lI!l ,~!,!Lh.O~no rmc pub li s ooc nn be h e ld r e spon s ib l e- f or i n jd r l5 . s uf iU ll ne d wh i le rO 'I lDWin&Ibr pi'Ol:edurt:~ deY:-r tbed.

~.qu. Smd.dfmllctl.tlg;!~1I]GAfI"tECHNOLoGY. "Thoe-JOYl'RlO fGC- I I 1 Man l lfa r nu ing .. 1425Lunl Avenue. P.O. Ba -~ 1;426. ElI i:Growe VillllC'~IL soon.:on~na c:opyriJhtcd by RANDALL Pl, JiBUSHINO. INC. ~991. Ar

tkles IppCaring in GEAR T ECHNOLOOY rna) 00 1 be ~ ~n".-boIe orIII p.n ....tl iout lbt IC."ApthS prnni~ion uf Itie publiJMf (Jf die- 1U0I0r

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9/68//lJiir'"7ffyARCUT SALES" INC..&/~34611 lndustrial Park DriveFarmington Hills, MI 48335 W e a r e m a n u f a c t u n r s . I n d s u p p l l l l r s o . h o b s ,f o r n t - . . . U e v e d Cuttlll'S. I p r e s l u N - c o o l a n t fllmln,gundriJls,IDDlllolderl;, c O l t i n 9 L . ad m a c h i n elools. W e l -I S D I p r o V i d e l a pUcllaD e n g i n e e r i n g "

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G ea r E x p o '91O p en s in D e t r o i t

AGMA's Gear Expo '91, "Theopens Oct, 20-23 atorld of Gearing,"

Cobo Conference & Exhibition Center,Detroit. Ml. Gear Expo '91 will provide 35,000 square feet of exhibits by 91companies from around the world.

P ro du cts a nd p ro ce ses on d is pla y i nc lu d e broaching. custom gears. cuttingroo~, fini hing, forging, grinding. heat treating, hobbing, inspection, l'ubricaling.milling, shaping. shaving, and te ting,

Showhours are L2:oo p.m. to 6:00 p.m. on Sun-day; 10:00 a .m. to 8:00 p.m. on Monday; 9:00 a .m. to

6:00 p.m, on Tuesday:and 12:00 p.m.. to 4:00

Hotel, Renaissance Center, a short distance from

p.m. on Wednesday.Once again tile AGMA

Fall Technical Meeting Iwill be held in conjunction with 'Gear Expo. TheFfM will be held on Oct. 23-25 atthe Westin

the obo Center. This year's meeting has beenexpanded to allow for more presenradons. The

papers will feature a variety of gearing subjects, including 3-D contact analy is,gear tooth friction, gear tress di tnbution, oil jet gear lubrication. and [ow-noi e marine gear.

F or m o re information about eitherGear Expo '91 or the Fan TechnicalMeeting, contact AGMA headquar-tersat (703) 684-0211 .B GEAR T~CHNOLOGY

Booth 0.717-719-721AGMA(7m) 684-021. I

Booth No. 337Ama r il lo ' G ea r Comp an y(806) 622-1273Boo th N i l. 137

Ame ric an Me ta l T re at in g C ompa ny(216) 4314492Booth 0.101Ame r ic a n O e rl ik o n(708) 810-0050Booth No. 30 tAm eric an P fa ute r L P.(815) 877-8900Booth No. 433BHS Hof l er Mas ch in eb au GMBHRepublic of Germany(07243) 9910Booth No.600Bourn & K och M ac hin e T oo l C o.(815) 965-4013Booth 0.441Ciareq he0 11 (5 2) 4 2 16 38 09Booth - o, 445fel lows Corporation( 80 2 ) &86 -8 3 3 3Booth 0.604GMI-Fhusa708) 986-0756Booth No. 125GMI-Mut chler(70S) 986-0756B oo th N o. 335

Gea r R e s ea rc h I ns ti tu te(70S) 241"0660BOOlhNo. 512Gea r Technol ogy(708) 437-6604

Booth o.536-538Gu eh rin g A u tom ati on I nc .(414) 2464994Booth 0..425Hofler l lMT Division of C arl le is . Inc.(612) 533-0'225Booth No. 238Hommel Ame ri ca(203) 827-8500

B oo th N o. 515-614[IT Research Institute(312) 567-4000Booth No. 627ITW-ULinois Tools(708) 675-2100Booth 0.625ITW-Zero Sy tern(708) 867-5857B oo th N o. 639J ames Eng in ee ri ng(303) 444-6337Booth No. lOtK l in g eLn b er g Ge a r T e chn ol og y , I nc .(216) 572-2] 00

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Booth No..24.1Koe pf er Am er ic a, In c.(708) 9314121Boom 0.213M 8 r . M Precision Systems(513) 859-8273Boolh 0.247Mikron Corp. Elgin(708) 888..0 13 2Booth - o. 525

Mitsubishi lnt.emational Corporation(708) 8604222BOO IhN o . 5 2 1MillS & Merrill(315) 629-300 1B oo th N o. 240Niagara Gear Corporation(716) 874-3131Booth 0.225Normae, I nc . .(704) 684-1002

Booth No. 120-122Pe rez M l Ic h ine Tool Co. (Okammo)(716168&-6982Booth 0.301Pfauier-Maag Cutting Toot L.P.(815) 877-8900Booth 0.242Precision Gage Co.,lnc.(312) 586-2121Booth No. 439'Profile Engineering, Inc.(802) 8859.176Booth No..341Reef G ea r M an ufa ctu ri ng . In c,(313) 9492520Booth No. 432Rcto Technology, Inc.(513) 8598503

B ooth - o. 64 4-64 6Russell, 'Holbrook & Henderson, Inc.(201) 6704220Booth o. 549-648Skidmore Gear Company(216) 442-6670Booth No. 201

SI!lfCU! Sales. Inc,(313) 474-8200Booth No. 347Tifco, Inc.(313) 6247900Boeth No. 718Tocco, Inc.(313) 3998601

BOOLh O. 606-608610United Tool Supply(513) 7526000800th No. 633WMW Machinery. Inc.(914) 3583330Booth No. 247Winterthur(508) 831 ~7918

T hes e G ea r E l\p o '9 1 ex hib ito rs areGear Technology advertisers.

I

I

C IR C L E .0 .8 on R EA DE R R EP LY C AR DSEPTEMBER/OCTOBER 1'991 9

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education system needs W be directedt owa rd t ea ch ing subjects usable in theworking world. 1 also believe thor re-quires the input of every mom and dadand all industrial leaders. All Q f us.may need 1 1 large dub to get the educa-tional.community's attention, but involve-ment is in everyone's best interests.That tips. my hand . I believe that in-

volvement. in education, at all levelfm mprim ary th rough grad uate. doe. omething towardaddre sing "indus-try solutions" through training and re-. e arch, U training and research co texceedtheirpayback; then we are teach-

A W o r d In E d g ew i s e

VIEWPOINTDear Editor:Re: Your editorial and "Viewpoint" byJo e Arvin ..Both you and Mr. Arvin make some

valid points. Your editorial appear tobe a response to Mr, Arvin's "View-point." This is a response to borh,The first point you make is that we

cannot depend upon any segment of thegovernment complex to assist in "fix-ing" the problems of the gear indu try.The second point is that the industry

lastly, I believe, your point isrhatomething mus t. b e done.Mr. A rv in notes the amazing growth

of the gear indu try in the Asian mar-kets he and the INFAC affiliates vis-ited. He points out that the equipmentthey saw was at or near "state of theart." He also points out that Asiancountries have invested heavily intraining and re eareh, Noted too isthefact that less attention seems to be paidto worker safety in some countrie ..H is v ie wp oin t reiterates the posturethat company training would put hiscompany at a price disadvantage withhis competition.Much of this is true, but nothing is

said as to why these condirioesexist,Better understanding of the re as on s fo rthese differences should lead to betterplanning for com penriv enes .In aU of the countries men tio ne d, a ll

must develop its own solutions. And government agencies, the bankingcommunity. and the industrialcomplex work in consort to developand advance their busine inter-ests and markets. Some of this itrue for many European countriesas well. In this country and withour system, not only is this Improb-able, but illegal. Anyone expecting"a level playing field" within hiyoungest grandchild' s l.ifetime isan extreme optimist. Understand-ing this may asist usin developingplans for better posturing.The previous paragraph leaves. "allindustry olution," "doing Some-thing," and "training and research"te be addressed. I believe lha.1 these arev irtua lly the s m e or so interrelated thatIannot separate them.It ha long been my beliefthat our

~lIusfol' lhi columnshould be addressed to:

Leuers 10 th e Ediror,GEAR TECHNOLOGY ,

P .O . B ox 1426. Elk.G ro ve V il la ge . IL

6 00 09 . N am es will bew it hh ea ld u po n r eq ue st ,

howevl'er . flO" no n ymou s l et te rs willbe pu iJH f / te ( / ,1 1 0 GEAR TECHNOLOGY

. I . . . . I . . . . . . . , . . . , . ,. , .costs exceedlhe ir I P l a y -

i n g a!nd S l u d l y i E l D g tihle'::I .I ., . ,, . ,ng and studying th e wrong things.While INFAC and the nTRI gear

research facility may address someofthe education. and research needsof the gear indu try, they may al 0prove the terrible state of our ma-chine tool. industry ..Other social andindustrial communities have bandedtogether to produce facilities ;imilar to Phitllps Govemmeat Train ingCenter and Precision EngineeringInstitute and have expanded theirind us trial b ase and b een less sens i-tive to recession than areas of thecountry that. have done nothing!

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One additional point I would Ijke'to.make is that the gear communityhas not been i upportive of Ameri-can machinery manufacturers andvice versa, Maybe a solution lies ina program simHar t o . that used by vari-ous agricultural sectors ..They contrib-ute money to. SUpPO" t hei r r es e ar chand maIketilng effo rts to a n. industrycouncil [hat. distributes it where theybelieve i .t reaps the greatest reward.WhatiLevery gear manufacturer in

A merica were to ' pu t $ .O Ol/pound ,ofgears cu t into a.Gear Technology De-velopmentFund accumulated and ad-ministered by an industry coulllcil?Tbemoney could be directed t o . areasofneed illthe industry: materials research,heat treatment research. 1.0.01develop-ment, machine development. No Gov-ernmentl No. Banks'! No Interest'! Stateof the Aft American Macbine ToolslMaterials! Methods! For An!!!'I mean to include everyone cutting

gears of all types from the largest tothe smallest instrument gear, includ-ing the autometwe, HD, and agricul-tural industr ies . .. .EVERYONE ! SomeFUNd ! Mayb e the amount needs to beOD~y $.OOO[fper pound! Who. knows?'Can an. industry council that. encorn-passes everyone manufacturing gearsbe Illegsl? Is the Beef Council?Will we let petty differences keep

us fromarming ourselves to do battlein the world marketplace? If the Asianexperience has not taught us enough,are we waiting for tb.e European Bco-nomic Commllility to teach usthe restofthe lesson? When will we learn?Has educauen failed. us? Completely?There isa way toaccomplish more

than anyone making gears todaydreamed possible toa greater extentthan imagined! Do we have the re-solve? If not this way, there are oth-ers ...Th.e question remains. "Do wehave the resolve?"

Clem MillerMiUer & AssociatesCrownPoint, IN

ENVIRONMENTAL CONCERNSl in r esponse to, conce rns fo r t he env ir onmen t, G E A R T E C IH N O lO G Y no 'l onge r usespolY:bagst,or its magazines. A s a result, some of you h av e re -ceived books that have been badly damaged. We arechang ing our paper ill an ef-substantia l, but we would ap-y o u a re s til l hav ing p roblems.

f ort t o make th e book:morepreciate hearing.flr,om you ifWe k_nowmany o ryou save

your books as a resource', and we ho pethat wei can coma up,with a so lu t ion that will help YOII and hel'p the environment Ifvou ra -coiv,e'si badly damaged boo'k, please contac t us at 708437-6604 .

SEPTEUBE'R,OCTO'BER. l'UVl 1 1 1

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S ee IUS 8.t BOOlih #213,

Part blank andgear c!Lttlng tools,play crlt,ioal Il'Oles i'1gur 'Cl,uality control!.We , o lfe r o ptio na l s oftware ' packages for in -s pe c ti ng l g e ar b la nk s forcircular geometry and gearcutting toots such as hobs,shaperlshaver cutters,an d broaches.

G e ar T e stin gl u sin g 'G e nerativ e Metrology tech-nique,s is ,enha l 'leed by,computerizealauto-malian, and analysis. True index, I'ead,and involute testing are performed

as the lesl part and probe' areengaged i n i l' ll er -r ela te d con tin uous move -ment . 'Rotary and l li ne a r a xi s a re s y -n eh ro nl ze da s reqU I re d by 'the leSl-

IndRl!IPnxess cOl'llrollcan be, Implemel' l tedl by anal-yzing data collected,I n gear testing'. Weoffer S P C software10 evaluale x - b a . r , IA .histogram, andtooth surfacetopol'ogicalstudies.

90124 ac ' Ge a- , A n a' l: yz er I so ne , , of a family of our geara nd gear , c ut ti ng tool analyiem.For a free, full-color brochure,d es cr ib in g o ur G e ar a na ly ze rs ,write or call M & M PrecisionS ys te ms , 3 00 Progress Ad.,West Carroll ton, OH 45449,5131859-8273, FAX 5131859-4452 .

.M&MPRECIS/eNSYSTEMS

AN ACME .. cL E VE L AND COMPANY

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C o m e S e e U s I n D e t r o i tctober iUle time. Detroit. is the place. AGMA Gear Expo '91 is the event. CaboCenter in downtown Detroit is where you will want to be in October if you haveany interest in gear products, m an ufa ctu rin g, o r research ..Gear Technology will be at Gear Expo '91 too. Come and visit us at Booth No.

512. Welook forward to the opportunity to meet with you, our readers and advertisers.Bring us your suggestions and ideas for the magazine, or just stop by for a chat. Find outabout how our new readership among people who BUY gears and gear products and ourincreased circulation can help your sales. Ifyou have an idea for anarticle or a suggestion for the magazine, this is the place to discusit. BU f you don't need an excuse at all Jus t drop by to s a y, "He ll o. "Gear Expo '9] will be an exciting place 0 be. At the time we go

to press .ninety-one companies are planning to be there, demons t ra t -ing their preducrsand services. The latest in equipment and pro-cesses win be on display. Ifou are planning on buying equipmentor are just "tire kicking," this is the place to see what's available inthe marketplace.

By taking advantage of AGMA 's Fall Technical Meeting, whichwill be at the Westin Renaissance Center concurrently with the GearExpo, you and your employees can. refresh and update your basicgear knowledge and keep abreast of some of the latest in gearresearch from orne of the best engineering minds in the industry.This kind of double-barrelled opportunity, targeted directly at the

gear indu try, shouldn't be missed. If you ve ever been IOSI inthecrowd alone of the giant trade shows or spent hours searching forthecompanies you were interested in, Gear Expo '91 will come a apleasant surprise.Its smaller, more intimate size makes for comfortable and friendly fact-finding.

Because Gear Expo is devoted exclusively to the gear and gear products industries" theproducts and services you need are easy to find, and you don't have to fight the crowd toget up close enough to see and hear productpresentations and demonstrations.This the fourth time AGMA has produced a trade show exclusively for 0\.1 industry. It

began as a small table-top adjunct. to the Fall Technical Meeting and has grown bigger-andbetter every time since. It is a valuable service, bringing buyers and sellers together underexcellent conditions for doing business. It deserves the support of the entire industry.

-PUBLISHER'S PAGE

Michael Goldstein,Publisher/Editor-in-Chief

SEPTEp,!BERIOCTOBER 199; 1 3

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E v o l u t i o n . ,

I 3 5 0 0 ' B e . Man invents the wheel and says "it is ,good"2 5 0 0 1 B C Man invents the spline and says "il is good"2 4 9 9 B C - Man i n v e n t s the spline gage and says " i t ' l l do the tric k"Man h a s been using the same spline gage ever s i n c e , T hat is, untllF R E N C O redes ign ed the gage for modern man. T h e IFrenco indicatingspHnegage p r o d u c e s v a r i a b l e ' data on e xact P itch D iameter whilesimul taneously checking: "GO" cond itio n . T his SPG compatable gagea lso quickly checks tape r, o va lity and o ther n r n e consuming inspections.Available for l in ternal , ,exl ,ernal , straight or l involute spl ine configurations.lei us show you a system for today a nd b eyon d. Ca ll or w rite :9 u e h - r'-.n- g - = W 2 2 7 N 6 1 ,9 3 S u s s e x R o a d l. ~ . - - - - _ . P . O . Box 1 25 S u s s e x , W I I 53089'A U T 0 M A T ION INC ( 4 1 '4 ) .2 4 6 -4 9 9 4 0 F A X ( 4 1 4 )2 4 6 -8 6 2 3

' C LRC I .JE A35 on R EA DE R R EP LY C AR D

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James Engineering 11707 McBean, Dr.. EI Monte, CA 91732 18181442-2898' F ax 1818) 442-0374C I R C L E 1 1 . - 2 2 on R EIID ER IR EP ,lY C A. 'R D1 4 GEAR TE.CHNOLOGY

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N O RT H A MiE R IC AN H EA DQU AR T IE RSKL iN G EL IN BE RG G EA R T EC H NO LO G Y, I N C .15200 F OL TZ IN DU ST R llA l P A IR KWA YS T R ON G SV I L L E , QH 44136P H O N E : 216 572~.2100F A X : 21'6 57. 2 -0 985

A DV ER TOR . I A L

KlingelnbergGeared to Progress

' W OR L I D H E A DQ U A R T E R S ,KU NG E IL NB E IR G S O HN EPETE F I S TRA 'E 1E 450 5 60 9, H U C K E SW .A iG E NTE LIEX : 85113196.TEL . (02192)811T E L I E F A X : (0 21 92 )8 1- 20 0

Klingelnberg .. II tradition of growth. Sinceits found ing in 1814 ,as a trad ing company,Klingelnberg bas c omb in ed in no v ativ e th in kin g.eons is t en t . .reinvestment in th e busines and newt.e clm o lo gy to p ro gre ss iv e ly s er ve th e gearmak-i ng i ndus tr ie s .In the early 1920's .. the companyentered th eg ea r i ndu s tr y. T h ro ugb t echno log ica l d eve lopmen t.a nd b us in es s acquisitions, the com pany haseme rg ed as an m rema tio na l k ad er fo r g ea rm ak in gequipment. The product line has grown to ill-d u de .... s pir al b ev el g ea r g en era tin g a nd g rin d in gequipment. hob sharpeners, worm and rotorg rin de rs , a nd a c om p re he ns iv e lin e o f a na ly tic algear inspection a nd d ia gn os tic e qu ipm en t. W ithth e grow ing reliance on CNC equipm ent,Klin ge ln b er g eng in ee rs a nd . c ompute r e xp er tsh av e ad van ced th e cau se o f au to ma tio n with in -n ov ativ e d es ig ns a nd s oftw a re to f ac ilita te f as te r,m ore accurate prod uction rates-w ith sens ib lep ric e p erf orm a nc e r atio s,Our latest development. ... 'th e j oin t v en tu re o fOe r] ik :oD -B ii hr Je AG (Zu ri ch ) w i th K l ing el nb e rgw i l l i resul t in fu rth er a dv an ce s fo r g ea rm ak ers , ..worldwide,

Collectively, th e c omp an ie enjoy an nu al. a le se xc ee din g $ 1.5 0 m illio n w ith o ve r 1 20 0 emp lo y-e e s d e d ic at ed [0 g ea r in du stry ac tiv itie .Klingelnberg "Puts it . all together"fo r g ea rm ak ers w ith ...Spir,al Bevel G'ear Applications KNC 40/60 Fully CNC Contr olle d Geaeratnrs AMK Large Gea r Gener at or s" W NC -80 G ear G rinders CNC Inspection Equipment Q uench PressesWorm and Rotor Grinding Applications" H NC Series of C NC C ontrolled G rinders" eN C Inspection Sys tem sP~ ra lle ll A x is G e ar Ap plic atiio ns" C NC C ontrolled G ear Inspection S ystem s" SN C Series of CNC H ob Sharpeners" G ear C utting T ool Inspection S ystem s H URTH product line: CNC Shavers , H ard &

F in e F in is he rs , S ha vin g C utte r G rin de :rs a nr'D e bm rin giC h am fe rin g E qu ipm en t

C IR C LE 11.-2 4'on IR EA DE R IR EP L Y C A'R D

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Iy ou "re a D es ig n E ng in ee r,you. now th e meaning ofp re cis io n. M is s by a m il andyou mi. s by a mile. NiagaraGear i~ \, contract manufacrurero f p rec i~ ion ~ pu r. h elic al a ndp u~ p g ea r.. 10 AGMA C las s 15with crew ning. We ar ee p ec ia ll y proud of ourreputation as a R eish auerg ro un d g ea r s pe ci al is t, N ia ga raGear 1 1 5 q ua li ty i ns pe cti ons ys tems in place 10 me et M IL -1-4520 and CalibrationS ta n da rd M1L -STD -4 5 66 2A .ital [llch Inspection an dChar l ing an! ava il ab le . N iagaraGear de li ve rs . On price. Onqualily . A nd on tim e. W e an!as c lose ' a ph on e ca ll aw ay .

94 1 Mililary RoadBu f fa lo . N .Y . 14217

ne ; (716) 874 -3131F ax : ( 71 6) 874-9003

C IR C LE A -12 en R E AD E R: R E PL Y C A 'R O

T H A N W ES E L LI G O O D W l l L I N ' DUSTR I IES

W I E T R A I N I T H I E B i E S , TW O RK ER S IN A ME RIC A ., '1 6 GEAR TECHNOLOGY

ADVERTISER INDEXAGMAAmerican Metal Treating Co.American OerlikonAmer ic an P fa ute r, L .P .Andrews 'Product .Jnc,Axicon Gear CompanyB H S-H ofle r M as ch ln eb au GMBHBourn & K och M ach ine T oo l C o.Cehfornin Bevel Gears, Inc:.Ciateq A.C.Fairian GearF or es t C i lY Ge a rGMI-Am aGMI-MulschlerGear Research InstituteG ue hrin g A utoma tio n, I nc .H ig h N oo nHofler/IMT m v . o f e ar l Zeiss , Inc.H ommel Am eric aITWmino.is ToolITW Zero Sysl.emsIn te rc on tin en ta l ln du trie s. I nc .James EngineeringKlingelnberg Gea r Techno l ogy , Inc.K o ep fe r Am er ic a. In c.M &M Preci ion SystemsManu fa c ilU r ed Gea r ,& GageMe t al lu r gi ca l. I nc .M ik ro n C o rp . Elgin

PageNumber49,5462

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Mitsuhishi Heavy Industries. Inc. 55 , cover 4Mitis &Merrill 52N ia ga ra G e arN o rm a e. I nc .Packer EngineeringP er ez Ma ch in e Tool Co.P fa ute r M aa g C uttin g T oo ls , L .P .Precis ion Gage eo. . Inc.Profile' Engineering, Inc.Pro-Gear Company . Inc.Reef -B a k er Co rp or at io nRote Technology, Inc,Ru ss e l] , H o lb ro o k & Hender son , Inc,Skidmore near CompanyStareut Sale Inc.T if co , I nc .Tocco. Inc. (Subsidiaryof Park-Ohio Industries. Inc.)U n ite d T oo l SupplyWMW M ach in ery , In c.Winter thur

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S in g le F la n k M e a s u r i n g ;E s t im a t i n g H o r s e p o w e rC a p a c i t y

Roben E ..:Smi~hand R oben Er r iehel lol

Question:. What is funerinnal mea-surement and what is the best methodforgetting: truthfuli answers?The main function of gearing is

to transmit uniform rotary motionand power from one shaft [0anotherat the design ratio of the gears. If thegears do not do this, they are said tohave transmission error .. Therefore,a true functional measurement of :gear quality would be one that

of gear characteristics, such as pitch.runout, involute. tooth ali gnment(lead), and tooth thickness. Thesemeasurements are typically made bya probe or stylus device that explorespart of a tooth or gear.Composite (Functional). Compos-

ite measurements are made by runningtwo gears together (usually one is amaster gear) in a manner that simu-lates unloaded operating conditions.

evaluates errors or variations in : Theresu1tingmeasurementsalieafullc-terms of uniformity of angular me- : tion of a composite of the elementaltion, This would be a tangential: variations described above.rather than a radial measurement. The advantage of elemental mea-Gear Quality measurement is done surement is in diagnostics. Becau eby either elemental or composite one is measuring discrete characteris-methods. The resulting values are tics, it is possible to sort out variouscompared to the customer's specifi- causes of any problem.cation or to some national standard The elemental method has three dis-for compliance. Any method used has advantages. The first is that the probeits advantages and disadvantages. cannot explore all parts of a tooth sur-Elemental, E lemental measure- face, nor .3111he teeth; therefore, some

ments are made of discrete variations errors might be missed. The second is

D o ub le F lank G e ar T esting/ S 'in gle fla nk G e ar T e stin g

Measures variation [n center distance Measures rotational' movements.-ig. 1 . - Composite gear testing.

Addr,ess your year i!ng questionto our panell of experts. W riteto them care of Shop Heor ..Gea r Te lehnollogy , P . Q i . IB ,ox1426 . I E llk IG rove, ViU.age, IL1 6 0 0 0 9 ' . or ca U our edit,oriia,llstanat (7 0 8) 4 3 7 -660 4 .

Robert.E..Smithis the principal ill R.E.Smith & Co.i lnc . . gearconsultants in Rochester,N.Y. fie has 11\'('/" 40years , experience illgearing methods,manufacture, andresearch.R obert Eniehello,is tire princ ipal inGEARTECH, a gearconsult ing f irm in Alban,CA. He is a member ofAGMA. MME. and fIRegistered ProfessionalEngineer in lire State ofCalifornia.

SEPl EMaER/OCTOBER 19&1 1 1

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G E A :R : IliN S P E C T IO N S Y S TE M

nAccuracy . ; n Millionths"

S P AC IIN G /IN ID E X , L EA D , IN VO !L UT IE P R O F,I 'L E

SCheCk-400

1 8 GEAR TECHNOLOGY

'4 FUll'" AXISCNC MOVEMEN T POSITIONING BOTAR., 3,600,000,PLACES. COMPUTER ENHANCED PUtl DOWN MENU USER I FR IE N D LV P R O G RA M TIUCEABLE TO NI ST POWERfUL UNIT COMPACT DESIGN HIGHI S P E E D PRINTER C OLO R GRAPHIC ' P L O T T E R HIGH, RESOLUTION CRT TWO VEAR WARRANTV

CIRCLE A-14 on READER IREPlV CARD

. lpmoneEAR DES~GiNCAILCULATIONSO, fTWA HEH ow d oes it work?FIRSTYou define for each paramet.eJ'. such asr at io , c en te r d is ta nc e, p re ss ur e a ng le ,etc", a convenient set of valuesthat youar e r ea lly a bl e to use.

SECONDYou define yourperfonnance ne~regarding Pilling Life, BendmgL i fe .Scor in g P ro b a~ i1 it y , Re li ~~m tyLevel and Operating Conditiens.THIRD

You wait a few seconds until disengfinds out the best solution to yourspec if ic p rob lem within your particular.. poss ib ilitie: ,

GEAiR EXP'ODETROIT, BOOTHH441CIRClEA-15 on REA'DER REPLV CARD

Tablet C o m p a r i s o n 01 Single, I:D ou ble fla nk 'est,in g M 'eth od s

I ..! I Do ub le I fl an k C ompo site (S eo F i g , . 2 1I A d v a n t a g e s :

- lnexpens ive eQ.uipment-The' best way to mea su re tu nc ti cn al t oo th thicknessoGoodway to meas ure r ou g, hho, bbed pans t ha t a re to befinished by a s ub se qu en t o per atio n

-FastOurableD,isadvantages:-Not t ru ly f un ct io na l j ra dia lmeasurement)

'Contacts both sid es oH e eth {n otgood for d iagnos ing invo 'luteproblems!

oOoesn' t measure' accumulatedpitch var iat ion (afunctionalcharacteristic)

" N i o t good fo r n o i s e contro'lS ing le : f lank C o m p o s ! i t o ' (See l F i g ' . 3 1 '

Advantages-Truly functiona'i measurement'{tangentia'U

"Good fo r posit ional accuracy{accumulated p itch variat ion ,'G ood for measuring involuteeffectsGood for noise controlD;isadvantages:"Relatively slow':Equipment i s more expensive , anddelicate

that keeping track mentally of all thesediscrete measurement to determmewhat the functional. result wiU be isvery difficult. The third drawback ofusing elemental gear measurememjieswith the AOMA standards (AGMA2000A-88andAGMA390.03a):. Thesestandard are telerances for runout andnot accumulated pitch variation, Ac-cumulated pitch variation is a morefunctional measurement than runout.(See "Shop Floor," Ja:n/Feb, 199I.Gear Technology.) Also, AGMA 2000A-88 use a "K" chart evaluation ofinvolute variations, This method ia'tnecessarily a good control of profilevariations for noise problems.The subject of composite mea-

surement is more complex, To beginwith, there aretwo types of compos-ite measurement: double flank and

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flank, why isn't it used more? : the American automorive manu-In the past, the technology for: f'acturers, and most ofthern are

ingle nank te ting wa: n't readily : checked by double fl.amk.measuringavailable. Double flankeqeipment was : equipment. Could (hi. be another rea-simple. inexpert ive, and fast, and il's : ,OR forthe decline ofthe Americanhuman nature to prefer the easy ap- : gear industry?preach, Single flank te ling equipment Some types of gear are difHcuh tois a newer technology and is more : measure with amy v alid ity by elernen-expensive. Also. tolerances for single : tal or double flank techniques, Envel-flank results do not appear in the : oping worm wheels and bevel gearsAGMA tandards. : are among the e. Milch of the testingHowever. I have u ed single flank : i done subjectively by the II e of

measuring instruments for the manu- : contact patterns. Single flank testingfacture of highlyaccurate and rnooth : procedure allow quantitative mea-gears since 1955. It is still one of the: urerneru of the functional character-first and most important tools in my : istic ofllle e gear types. Single flankconsulting practice. : testing can be done on a sembled gearThe use of this equipment has been : trains as well as on loose gear. It is

more common in foreign countries. : very useful for gears used in printingProbably no more than 25 sy terns : presses, noi e en itive products, in-are in use in tile U.S .. compared to : dex mechanisms, robots, antenna di-well over 200 ystem el ewhere: : rectors. etc.yet there are more than 300 company The fact that single f lank testing ismembers of AGMA. Almost all of : slower than double flank i no longer athe existing equipment. was devel- : valid reason for not using it. With theoped and manufactured in Europe. : introduction of statistical techniques,One such in trument is made in : such a SPC, in the American aurorae-Japan. Another system, developed: tive andother industes ..lhesingleflankin England, is now manufactured : method can be u ed to te t small.by an American company ..Mill ions: ample on a regular basi. The trendof gears are made every year by : isto gel away from [00% inspection.

.-- _.,: such a. is usually done with double: flank measurement,: Question: Iso't it lime that the Ameri-: can gear industry gave erfous: thought to the use ofsingle flank gear: testing equip,ment?

Yes!'!!

single flank (transmi sian error}. Un-fortunately, the double flank methodhas been .0 common in the pa t thatthe term "composite measuremem"has become almo tgeneric to it.It is important to understand

the difference between these twomethods. Perhap if more peopleunderstood the advantage ofsingle f1ank cornposite measure-ment from a functional. tandpoint,it wouldn't be .0 rare.For a comparison, see Fig. 1 and

Table I. Both sides of the meshingteeth are in contact for the doubleflank method. Only one side is incontact for the ingle flank. method.The important differences are:

I.. Tile double flank method mea-sures variation in center distance, while[he single Hankmethodmeasures varia-tion in rotational movements.

2. Most gears never run with bothsides of the teeth in imultaneouscontact. Therefore, single flank isthe truly functional method.Question; U ingle Hank measure-ment is 0much better than double

Sdae . . . . 1ic o r Co :m . po l1 e M IWaTu& nmc.

: Question: We hav e r ec on s tr uc te d iii: tr,iple reductien parallel a j gear-: box which is driven by a 100 horse-: power electric motor. 1 & i. used to: drive a large . crew used illiwaste: proc,esing. We bave aU of Ihe gee-: metrical data, on all three gear: ets,: teeth. DP, PA.helix liIngle., face width,

L..- ....I : eenter di tance, etc. We k . I1DW the: gear materials, which are case car-

SEPTEMBER.OCTOBER , gg I 1 1 9F ig, 2 . - D ouble flunk c ompos it e a ct io n measurement,

.I

: To address questions to Mr, Robert E.: Smith. circle Reader Service No. 78.

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. G S 8-2H SMODEL ~. capacityGear Shaper. 12 snaperstl.......e ' f ro (1 110 c V" s"9"109s t P r ices lL owe I orders!speer!! ., It SelVleeB eS call forname alrePm yo urare8

CIRCLE A-l 'S 011 READER REP,l.'y CARD2 0 GEAR TECHNOLOGY

- - - _ IOO',,"TOTOOTH

~Stl!l!AJON''---------- V-.-noN -~~~-----I

TOTAl .__ TRAN~VAJlAl'lON

F ig . ,3 - S in gle fla nk composite action measurement.

burjzed, and the gears are made 10AGMA Q-9 accuracy levels, The in-put speed is Iknown, and the gensoperate under a lubrlcatien system.Is it p os sib le to predict or esthnatethe horsepower a\,pacity and run-n in g h ou rs th at ca n b e e xp ected fromthis box? It so, how?Parallel-axis gear sets can be rated

using the methods described in ANSIJAGMA 2001-B88, American NationalStandard. "Fundamental Rating Fac-tors and Calculation Methods for Invo-lute Spur and Helical Gear Teeth," andAGMA 6010-E88. American NationalStandard. "Standard for Spur. Helical,Herringbone. and Bevel EnclosedDrives." These standards give equa-tions for calculating the power capac-ity of gear sets based 011 pitting resis-tance and bending strength. Also.ANSI/AGMA 2001-B88, AppendixA. gives methods for evaluating tilerisk of scuffing and wear. In addition

need the geometry of the tools used tocut the gears in order to calculate thebending strength geometry factors.The purpo e of the standards is toprovide common methods for ratinggears for differing applicarions, andto encourage uniformity and consis-teney between rating practices withinthe gear industry. Although most ofthe calculations are straightforward,some of the factors in the equationsvary significantly. depending on theapplication, system effects. gear ac-curacy, and manufacturing practice ..The engineering judgment of an ex-perienced gear designer is required toproperly evaluate these factors andobtain realistic ratings.Software is available for personal

computers that automates much of thegear rating task .

If you have questions/or Mr. Rob-ert Errichelio , circle Reader Ser-

to the data you mentioned, you win vice No. 79.

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We'veadded a newdimension in serviceand support to ouradvanced 3 -Ugea r-measuring machines.I l f y o u h a v e n ' t l o o ke d a t u s l a te ly " h e r e 's s om e b i g n e w s :H o fl e r e N C g e a J -m e a s u r in g m a c h in e s a n d l . s o t tw a r e n ow c o m efrom th~I~~dustrialMeasuningle~hnologx D i v i s i o n I

o f C a r l ~ e ls s . l n c , a w o r l ' d l e a d e r In c o o m m a t em e t r o l o g y e q u ip m e n tA s t h e g e a r e x p e r t s a t Z e is s , H o fl ' e r isn ow m o re r e s p o n s iv e t h a n e v e r . O u r f u l l : - s e rv io elocatcns a c r o s s t h e US. p r o v id e w h a te v e r y o uneen-saes, o p e r a to r t r a in in g , m a i n te n a n c e o rr e p la e e r r e n t p a r t s .An ex tr a d imen s ion ins pe ed a nd p re cis io n.

A l l H o t l ' e r m a c h in e s f e a tu r e a u n iq u e t h r e e -

d im e n s io n a l p r o b e h e a d t h a t a l l o w s f a s t e r , m o r e a c c u r a tet e s tin g o f p ro fi l e a n d~ le a d . I E v e n t h e s im p le s t H o fl ' s r m o d e lis m o r e p r e c is e ' t h a n a n y c o m p e tin g m a c h in e in t h e in d u s t r y .H o fl ~ e r p ro du c ts in c l u d e t h e Z M E s e r ie s fo r c y l in d r ic a lg e a r s , t h e E M Z s e r ie s fo r u n iv e rs a l g e a r m e a s u r in g . a n d t h eZ M C m o d ' e l f o r y o u r m o s t d e m a n d in g I l a b o r a to r y , 3 , 1 0 a n db e v e l - g e a r a p p lic a t io n s . Y o u c a n a ls o c h o o s e f r o m th r e ed i s tin c t s o f tw a r e p a c k a g e s t h a t r u n o n a n e tw o r k e d o r s t a n d -a l ' o n e IB M A T - c om p a t 1 i b l e o r l H ' e w l e t t ~ P a c k a r d c o m p l l t e r .C all t od ay fo r literatu re o r 3. d.emonstration.1 -800 -888 -1967Ex t .51

Or see your l ocal Ze iss representa ti ve .C a r l Zeiss, I nc .IMT D iv is ion70 08 N orlhlan d D riveMinneapolis, MN 55428612 533' 0225

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New H ob ProductionM ethods in P lace atStar Cutter Company

A DV ER TOR I A L

MANUFACTURE OF PRECISION HoesE MP LO I:N IG N E WL Y D E VE LO P E D ' T EC H N O LO G Y IS , T H E

L AT ES T S TA R ,IN NO VA TII!O N I.

In response to the demands of theautomotive and other industries for faster-running, quieter transmissions under heavierloads, new methods developed at Star nowproduce precision hobs having a super finish.Hardened hobs are finished by skiving or bygrinding, depending on the hob geometry, Thevast majority are skived. In the past wefinished hobs using an EDM process, Thismethod has been discontinued.Under this new method all hobs are vacuum

heat treated in CNC equipment to ensureextreme accuracy and uniformity. Superiorheat treatment is vital to proper applicationof the new hard finishing technology. Testsshow that our new hard finished nobs givelonger tool life and consistently producehigher quality gears. Their hard finished sur-faces readily accept titanium nitride (TiN}coatings and other advanced coatingtechnologies.In developing this latest innovation we

called on an amazing array of specializedtalent and resources. The structuring of ourproducing units and the people who managethem and work in them are truly specialized.We subscribe to the "one product/one plant"philosophy because we have learned through

2 2 oe A 1 '\ TECWi'lOLOGY

the years that quality is higher and productionis optimum under this arrangement, We cur-rently manufacture hobs, form. relieved cutters,pressure-coolant reamers, and gun drills, A Uare manufactured under our one product/oneplant philosophy ..We also operate two coatingplants, a carbide preforms facility. and amachine tool manufacturing plant, Theseautonomous units, strategically located acrosslower Michigan, funnel their products andservices through our sales and service division,StarCut Sales, Inc., located near Detroit inFarmington Hills, Michigan.Yes, we call ana wide array of talents and

resources when we undertake an innovationsuch as this new hard finished hob productionsystem. The specialized experience 'of peoplein all our plants in such disciplines as hardmachining, heat treating, coating, CNC,statistical process control, and quality controlwere brought together on this project. Ourobjective was to produce the most accurate,productive hobs on the market today and toback them with timely and experiencedproduct service. We feel that we have accom-plished this and that hob users will agree.There is a "continuity" of leadership at Star

Cutter that has made it possible to assemble

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ADVERTOR I I A L

Skived hobs and closeupof skived tooth.

the talent and develop the plant facilities thatwe have today. Since its founding in 1927. Starbas been headed by a member of the Lawtonfamily. Norm Lawton took over activemanagement of the company from his fatherin 1942 and is president today. He is ablyassisted by his son, Brad Lawton. the firm'sexecutive vice president, One grandson, Jeff,has headed the corporate qu ality c on tro lprogram and is now managing one of theproduction plants.There is an "extended family" feeling at

Star Cutter that is the result. of wise leadership,manageable unit size, and a policy of pro-motion from within. All plants are managedby people whose careers began in a shopposition at one of the Star facilities. These arepeople who became "hands-on" familiar witha particular product or service, often went

outside for further education, and returned toassume management roles ..Visitors often com-ment on th e h ig h m orale o f o ur em plo yees an dthe industrious atmosphere in our plants.These are things that result from this familyfeeling.Wi.th our extensive specialized resources,

our highly motivated employees, our dedi-cation to quality and service.uurawarenessofand willingness to change with changingtechnologies, Star Cutter Company look:sforward to further growth in serving themetalworking industry. In the words of ourpresident , '''We'n find a w ay or mak:e a way."For further information regarding our new

line of hobs, contact our sales and servicesubsidiary: StarCut Sales, Inc., P,O..Box 376,Farmington, MI 48332~03f6; phone3]3/474-8200; EAX 31 3 /4 7 4- 95 18 .

Ground hob. and eleseup01ground teeth.CIRCLE A -19' ! ! ! '! R~ADER REPLY CA'RO

SEPTEMBEA/OCTOBEA 1991 2 3

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lntrooucim

T O C C O P r o f i l e H a r d e n in g

At Ilast. .. there's a gear hardening process that providesexna hardness/strength at the pitchline, and optimumstrength gradient at the rootfi llet - withoutexcessiv~heating and brittleness at the tooth tip. TOCCO ~roflle _Hardening (TP'H), a new, highly automated and field provenprocess developed by TOCCO, merge~ 3 distinctivetechnoloqiss: Programmed Preheat (AF-Iow frequency),'High lntsnshy (RF - high frequency) and IncrementalHardening ..A II can be comprised in a single, compact,totally integrated manufacturing cell. *Another TOCCOadvantag.e: The proprietary TPH processusually uses less than 200 KW rated power supplies (AF &RF),. So, you don't need an expensive substation, asrequired by older design contour hardening systems.

Photographed a t TOCC()'Boaz dur ing' run-of

TPH provtdes gearmakers with: lincreased strength Reduced distortion Improved metallurgy, Hliglherqualiity Lower installation costs Reduced operating costs per part

Contact your TOCCO representative' fo r detailed .informa-tion on TPH ... the most advanced, selective or surfaceg;~ar-Inardening/tempering system available' ... anywlnere.TOCCO, lnc., Sales, Service and Technology Center,30100 Stephenson Highway, Madison Hts. MI 48071.Phone 1-800-468-4932. In Michigal1 31'3-399-8601.FAX 313-3998603

A Sub sid ia ry o f P a rk -O h io In du strie s, In c .C IR C LE A .2 0 on R EA DE R iR EP LY C AR D

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ADV , ER lOR l i A L

Induction Profile H ardeningEnhances G ear PerformanceroCCO\ Inc. h as developed a multi-

f re qu en cy /m u lti- cy cle " Pro file " in d uc tio nh ea tin g p ro ce ss w h ic h a llow s g ea r m a nu fa c-tu re rs to a ch ie ve superior s tre ng th a nd hard-ness at th e m ot fillet and pitch lin e o f a geart oo thw it hou t g en er at in g exc es si ve h a sd eni nga nd bn tt le n es .at th e to oth tip .The TOCCO P ro file H ard en in g I(T PH )

p ro c es s i s f ie ld p rov en . Comme rc ia l i ns ta ll a-tio ns in clu de a. fu lly -au to mate d lin e at th eYpsilanti , MI" Powenrain div ision of Gene ralMo to rs , T h is s ys tem p ro file h a rd e ns in te rn algear forw ard dutch hous ings and sun gearoverrun clu tch h ousing .Un l ik e c onv ent io n al d u al f re qu ency in d u c-

tio n processes w hich attem pt to generate au nifo rm ,e ne rg y c on to ur a cro ss th e to oth tip ,an d p ro file a re a, th e T PH p ro cess p ro du ce sa n on un ifo rm e ne rg y in pu t p ro fI le to c om -p en sa te fo r n on un ifu rm ity in th e m ass re la-tio ns hip b etw ee n th e to oth tip a nd to oth ro otarea. In ad dition to utilizing tw o or m orefrequencies , th e T PH process a lso is pro-g ramm ed a na tim e d ep en de nt s eq ue nc e, T h is

V a ria tio n s o f th is s ys tem wh ic h emplo y s ta tico r in cre men tal h ea tin g, sin gle o r m ultip lein du cto rs a nd s m alle r R F power supp li es wi llp rocess large and sm all O D and lD gears , asw ell a s m u ltip le fu nc tio n g ea r c om p en en ts .Multi-freqaeney/multi-cycle profilehardening hasproven to b e a c os t e ffe ctiv e

impr ov ement t o c onv ent io n al d u a l f re qu encyind uction h ard ening and gas furn ace car-burizing, T he prim ary benefit offered byTOCCO'S patented proces s i s superior gearp erf orm an ce . R o ot f il le t c ra ck propagation( to o th b r ea k ag e ], p it ch l in e s u rf ac e d egr ad a -t io n (p it ti ng ) a nd p it ch l in e s u b su rf ac e f ai lu re s(spatt ing) are minimized orel iminated.With respect tocarbur iz ing, th e TPH pro-

cess s ignificantly reduces in-process . inven-to ry , m in im iz es o r e lim in ate s p os t h - a.t tr ea tm ach i.n :ingand low ers installation andoper at in g co st s.The T PH process can b e operated In -

d e pe nd en tly o r in te gra te d in to a n in -lin e p ro -d uc tio n s ys te m o r m an ufa ctu rin g w o rk :c ell.TOCCO a lso has developed microproces Of-

aH owsextra energy/temperature to be ' based control, m onitoring and d iagnos ticgenera ted in th e m ot area w hile lim iting capab ilities to support th e TPH process,e n er gy i npu t to th e t ooth form . For more inform ation on the roccoTh e TPH process can selective ly harden TPH profile h ardening. process , contact

g ea rs m an ufactu red fro m p lain carb on an d ! G eorge D . Pfaffm ann, V ic,e Presid en t ofalloy s teel. as w ell as cast iron and pow derm eta l. S ev eral v ers io ns o f th e T PH p ro ce ssar e a va ila ble . T h e original process is forhardenin~ex terna ll d iameter gearsurfaeesaadinternal ring , spur and helical gears.

Technology and Serv ice Operat ions .rocco, E nc .,a su bs id iary o f P ark -O hi.oIndustries. Inc, 3 010 0 S teph enson H wy:"Ma d is on He ig h ts , M m 4 80 'H . O li c a ll o ur to llf ree number : 1-800-468-49.32.

C IR C LE A -21 on R E A D .E R R E P L 'I i' C A R DSEPTEM'BERIOCTOIIEFI 1991 2 5

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SPC Acceptance ofHobbing & ShapingMachines

B r i a n W . C l u f fA m e r ic a n I P f a u t e r I L i i m i t e d I P a r : t n e r s h i I P '

Loves Park . llToday, as part of filling a typical gear hobbing

or shaping machine order, engineers are re-quired to perform an SPC acceptance test. ThisSPC te t, while it is contractually necessary formachine acceptance, is not a machine accep-tance test. It is a process capability test. It is anacceptance of the machine, cutting tool,workholding fixture. and workpiece as inte-grated on the cutting machine. u ing a gearmeasuring machine. with its work arbor andevaluation software, to measure the acceptancedements of the workpiece ..Depending on the workpiece tolerances an d

desired capability (Cpk level), this acceptancetesr can be a relatively simple runoff, or itcan be a long, complicated procedure to deter-mine the source of variables in the system.Rarely is the bobbing or shaping machine a

sensitive element in the acceptance process.Fi.g. 1 shows the relative weighting of the criti-

WorkpieceFixtureCutting ToolMachineTopologyMeasuring Method

50.0%20.0%10.0%6.0%7.0%7..0%

Fig. I - Relative weighting ofthe criticalelements of the system in a typical gearhobbing or shaping 6 Sigma machine acceptance for size, lead, and runoutcriteria.Involute and spacing (pitch) are usually excluded as criteria for pre-shave and pre-roll gear operations, but included as criteria for finished hobbed and shapedoperations. The elementlabelled "Topology" refers to the flank topology ofa geartooth a produced by the feed ofthe cutting tool.and in the case of hobbing, to thenumber of threads in the hob.2 6 GEAR TECHNOLOGY

cal dements of the system in a gear hobbing orgear shaping machine.Usually. in the proposal stage for a machine

order where SPC requirements are defined,American Pfauter engineers reverse-engineerall critical elements of the system to establish ifthe desired Cpk can be achieved. Often, at firstglance, workpiece production tolerances shownon the workpiece drawing are practicallyachievable. But when the capability indexesare greater than 1.0, the reduction of the allow-able values often reveals tolerances which arenot readily achievable. In some cases the center-ing of the average value for a plus/minus 30'requirement exceeds the achievable accuraciesof the generating process. This is typically seenwhen attempting to conduct an SPC qualifica-tion for workpieces which will be subsequentlyfinished by another process, where productivityfeeds and speed alter tooth topography to a

Fig. 2 - Gear tooth flanks produced by high feed rate,multi-thread hobbing,

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level which belabors interpretation in the ana-lytical inspection process. Fig, 2 shows the flanksof gear teeth hobbed for subsequent shavingusing high feed rate .and a multiple thread hob.Fig, 3 shows theflanks of teeth shaped by the

CCP method for subsequent having.In general. CNC gear hobbing an d gear

shaping machine manufacriued today alreadymu 1 pa a serie of static and dynamicalignment and kinematic tests to be consideredready-to-cut. workpieces. Figs. 4a and b illus-trate ] 0 of the W 9 acceptance checks for a gear Fig, 3 - flanks of gear teeth shaped by the CCP high-feed-rate method for 'ubscquent shaving.

Standrudsof Acceptance for Ho bb in g M a ch in e P I2 5 1(in .cco~ v.ri!h D IN 8 64 2 ) With Spec ia l Accu racy I TR-73

S er ia l NQ : IIConsignee:Check IUIL'tratWII Mea su n n g l i l' en n iS S i blC MellSuredtool< de_wi"" .x:\,[ilfioo

~Gagoblocb 1>0.035 mm .;0,0351'IoID !1 - - - ~ J .r i lLHr. . . u- ~_._ CompanolQr",Jdeway

I l - I I J ICompmclO!fr u e O,02Omm D,O I .5r u r m n ,of_',,!>~

1\ A4 c_pvotarl o , w : n u n I O . O O SCQ[I ; 'Cfl- - . lr 'M;: It. .It)'or 'Work Bnrbar 0,015 mm D,008

I

I Ahs!~ru I.. 1\ 1\Ulnparalor O,QIS mrno(work.tburi B Bon

Procedure IPIa , "" 'gb te dg< B . .,,wopgtlll""bi\of,!lrn1ie.1 "'"8th place ,"","",,1II.1ode"lido I ~ 0,010 mrn 0,008 over full (en81h of If!i'Vrl:IIU&WU,)' and ROl.e-COnlpamtDrre ed me "

I Fl I A. II Poi~tlon c:omplrldDF onn f u i ! I O,OOS IT Im r'1 0 ,0 0-1 cneamrereeeeConccntri1:1cy "t' l U,003 of wor t e re ee .ofhoh CompMIIlOf RoolI< ho b 'p ,ndk-. B B >lowly.0.008""" "t'l a,DOg Tm~'At'l O , l l O R . . , . , . " " ' "Fig. 4a - Standards ,ofacceptance for a hobbing machine (DIN 8642). Te IS 1-5. Fig. lib - Standards of acceptance for a bobbing machine(DIN 8642). Te IS 6-10.hobbing machine according to DIN 8642 stan-dard.SPC engineers, 'however. attempt to accept a

hobbing or haping machine through the statis-tical evaluation a process by checking the prod-uct it p ro d uc es w ith ou t. identifying the inherentvariables, Often these attempts becomeexcruci-ating trials due to:a) arbitrary product 01' proces specifications,b) arbitrary component. pecifications,

c) out-of-control process, materials. andequipment.d) inadequate evaluation and inspectionsystem,'e) little understanding of gear manufacturingprocesses.A typical example is the gear manufac-

turer who expects an SPC acceptance test toa Cpk of l .67 011 a gear designed to AGMAClass 9 tolerances, yet suppl ies workpiece

Brian W . C luHi s V ic e P r es id en t, S a le s,(It American Pfauter, Ltd.He is the author of'1!!merD!/S books Qlldp ap er s o n g ea ri n.gsubjects and is a memberof AGMA,MME, andSME.

SEPTfMBEFlIOCToeeR 199' 2 1 '

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TA BL E: 1 I I I J c IJ I I J I I,EFFECT OF ,PC ON A OMA OUAUn g lOLER'At{CES ( A N& l 1 AGUA 2~AII)

I

V.T V'o1' I V,T' YaAl0.0004 0.00046 I 0.0011 0.000820'0002 m00023 0 . 0 0 0 5 < 1 , 0.D00413, 12' 12 120.00016 0.000t8 0.00043 0.0003214 12 12 12

0.00013 0.00015 0.00036 0.0002714 13 13, 13

GEAR DATA:: 18 TEETH 16.933 NOP I25.6419' HA 9483" FWI 11.1811' PO S lD G EO ME TR Y, N O MOD I F I C A T IO NS

E O U I , Y'. A G I I A QII !!LB

,e SAUPLIE SIZE "" TOI..CPK 1.33 491EaU IY . AGIIA at T 39.3PK 1.17 25EQU I I I ' . AGIIA QI '"':CPIC 2.0 25

INOTE: ,M stallstics baud o .n Ilnbtasad iisllma~ ofSD(X).R1d2

T A B LE 2! ItEFFECT OF REDUCED SAMPLIE, S IZE (PA'RT.TOPAR1i) ON AGMAOUAUTY 8T O I . E R A N C E S ON GEcAR'ID AT A IN TO,"E 1 'IG A A D A T A ' 18 TEETH 18.9G3NDP I

25.8419 HA 9483" FW Il.t811' PO sro GEOME TRY , 'NOMOO I F I C A T IO NS

V v . I _C-Vo v. 9~00004 I 000046 0'001t :0.000820.00008, 0.00006 0.00015 0.00012~15 15 ' 5 IS

0:00005 0.0000:5, 000012 0.00009'>15 >'5 >':5 >1 5o OOO!J;ll, I 0.00004, 00001 0.00008:>15 , .15, :>15 ,.1S,

A~IU TOLERANCE (Iantha)~ " f l SAIiPlE SIZ,E "" lOLCPKU3 I 2 14.1I E C lU I Y, A G M A atl 2 - - - rP,I( 1.11 11.3E aU IY . A ,G MA QlI

2 I g'.4EOU I , V . A:GII" at I

TABLlE3 I I I I ,I .1I I I I I IEI'F:ECT OF :SPC O N I AGI IA 'QUAUn ' I/TOLERANCES (ANSIJACl !MA :2000-AII ..1,GEAR O A T A ; IiG TEETH 5.06 N O P I I I18.2602' HA 1.868S' FW II

, 11.68' P D S TO G EOME TR Y. IN a MQOF I CA T I ONS ,

'hiT Vol V. T Vp AAGMA TOLERA'NCI! ('.nthal I . 0.00177.00065, 000120 0Q383,~, SAIIPI.ESI~E I""OI..

0.00058

CP K Ut3 .2.5 I '9 ' , 0,000591 I O.OOIU 0.0000870003512 12 1EQWY. AGMA at, 122I 39.3PK 1.17 0.00026 0.00047 0.00151 I

EQI I IY . "GIlA. at r .: 12 1'2 12C 'P !( 2 '. 0 25 328 0.00039 0.00126.00021IEOII IV: . . .. . GII.. !:WI 14 13 13,NOTE: All slatlstlCSbaud o n u"btased esfimal8 or SD(X).Rld2 ITable 1.2, 3 - The effect of SPC on AGMA Q uality 9 : 't ol er an ce s. (ANSI !AGMA 2000A88) L egend : V wT = To ot h a li gnmen t ( le ad )

V oT '" P ro fileV rT = Ra d ia l r un eu tVpA; ;; ; P i .l ch

2 8 GEAR TECHNOLOGY

b lanks at productioa telerances, which maynot comply to print specifications (Cpk 1,0)on characteristics. such as bore-to-face per-pendicularity and bore size, and which have110 tolerance or definition for borecylindriclty, bnre roundnessor bore taper.Purther, he demands maximum productiv-ity and inaists on multi-theeadhobs work-

ing at ihigh feed rate , (See Tables 1,2. and 3,)The inherent system variables in the gear

manufacturing process (see Table 4) can makeit difficult to achieve the desired capabilltyfor lead and involute. depending onthe speci-ficati.on width,For workpiece/workholding repeatability,

these inherent variables ca n be implied from th efollowing statements:I) Tile actual machine workholdJing axis of

rotarian must be identical to th e actual axis ofworkpiece rotation.

Center o f Ro ta ti onand /or S urface of L ocati n

ToothAIi.gn.l1lelll10Axi ofRotation 1 . . Center of Rota tion .a nd /o r S ur fa ce o f L oc atio n

o f Lo c at io nILeadTraceTo ot h A l ig nme nt (Lead)

ToothAlignmenl'10 A xis ofRota tion

o f Lo c at io nC e nt er o f R o ta ti ona nd /o r S ur fa ce o f L oc ati onIea d

Trace T oo th A lig nm e nt ( Le ad )

ToothAlignmentto A xis ofIRotation

I, IeadTraceF ig . 5 - T h e e ff ec t o f a xia l fa ce ru no ut 01 1 l e ad va r ia t ionon a clamped workpiece.

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2) Workpieces whose critical Ioeatingelements have not been identified and quali-fied to a compatible capability level willcause the statisticalevaluation to fail. Boregeom.etry variation impact lead, involute,an d radial runout error.3) Little bore geometry error means less

lead, involate, and radial ranout variation.4) Little axial face runout error means less

lead, involute. and radial ranout error. Fig.S iljustrates the effect o,f face wobble indetermining lead variation.5) Greater bore geometry error means less

contact between the machine workholdingfixtur,e and the actual bore of the gear ..6) Less contact berweea machine workholding

and the actual. bore of gear means greate rlead, involute, and radiel runout variation.7) Less random variation of number an d mag-n itu de o f b are g eem etry errors from p art to part

and th roughout a given sam ple of parts m eanslead, involute, and radi~ runout variation shallbe :in."statistical control."8) A greater random variation of number

a nd m a gn itu de o [l:> o ]',eI,eometry e rro rs frompart to part and throughout a . given sample~f parts .. m eans lead , invo lu te , and rad ia lrunou t variation sha ll be less "staristicaltycapable."For inspection workpiece/workhol.dingrepeatabijity the e inh eren t v ariab le can

be implied from the foUowing statements:1) At best, inspection workholding "ap-

proximates" the machine workholding axisof rotation,

2) , There is always a difference between ma-chine work:hoIdingand inspection workholding,which means that m e axis of workpiece rota-tion and the ax is of in pection rotation cannotbe identical.3) G reater rand om v aria tion of number and

magni tude of bore geometry errors f:rompart 'to part and th reughou t a giv en sam pleof parts m eansgreate r d ifference betweenma~hine workholdmg and inspectionworkholding, which means lead, involllte, andradial runout variation will be less "stati.stically capable. ".4) Inspection machine software, designed

1.0 draw the average trace of leads on feurteeth 90 apart and u ing the sum-of-least-quares method, can show random mead

Tab le 4 - Sources o f g e al ' e lement e rr or s.

G EA R E LEMENT rossrat.s SOURCEToot IJ Al igmnent(VwT)Oead)

Mac hin e ta tle a li. gnme nlsMachi ne t he n na l ~tabilityElec tron ic sync 'l tr on iza l ionva lues'(':00] wear (built.up edge )Measur ing m.achine al ign_mentsMe a su ri ng ma ch in e e v al ut io n'Software rout ines

Tooth Alignment(VwT)-var iat ioruwilhill a singleworkpiece

Work fixture a rbo r r ad i al i runmUAx ia l fa ce ru no ut of workpiece"Arborology" (How the arborf il ls t h e bore)

Measuring mac l: ti ne a rbo r r ad i aJ runoutT ra nsfe r e rro r b etw ee n c la mp in g o ncutting arbor and :measur ing . a rborGuide looseness (sha,per)F ee d r at es , h o b bi ng /s lt ; pi ng c o nd it io nN um b er th re ad s 'in h obTooth topography. (Fig. 7)

P ro fi le (VoT ) H o b n um b er o fllu ea dsHob shift variation effeciH ob rack fo rmHob le ad (in o ne tum of helix)Hob moullling on hob arborFace runout of workpieceElectronic sync'iuonizationresolution

Work f u tt ur e ar bor radialland3xiaI I1I InOui

F ee d r at esTooth topography. (Fig. 7)Hob buill-UP edges

R a d ia l r un o ut Work fixture arbor radial runoutWorkpieoebore size 10 arbord if fe re nt ia l ( so li d a rb e s)Wo rk p ie ce b o re c y li nd ri ci ty"Arbomlogy" (How tile arbor fillsth e b ore )

Measuring machine arborr ad ia l nmau t

T ra n sf er e rr or between elampingson cutting arborandmeasurillgarbor

(Vff)

SEPTEIoIBIERIOCTOBEF! III' 2 9

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fitch (VpA) Machine worktable driveElectronic d r iv e r es o lu t ionF ee d r at esNumber of ihreads in hobFlank topography "a s seen" bymeasuring machine probe

Size Machine X-ax.is settingThermal machine growthHob Ilute resharpening accuracyHob thread-to-thread errorFeed rates - hobbing /shapingcondit ions

Measuring technique

variation on flanks hobbed with muhi-threadhobs when the workpiece blanks showlittle bore geometry and axial face runouterror. (See . ! F j g . 6.)

Most manufacturer' purchasing ma-chines dedicated to a specific workpiece arenaturally interested in qualifying the systemto a specific specification. Once that speci-fieation is achieved, changing it to a higherrequirement al a later date may make theprocess no longer capable.

! F O ' f manufacturers purchas ing machinesto produce everal parts ' tovarious specificationlevels, the machine ystern capability demon-strated on the acceptance workpiece may not beattainable on another workpiece at anotherspecification level.

A verage Lead. ."

Fig, 6 - Effect of muhi-thread hob. thread-to-thread error on average leadvalue as measured. on four teeth 90. apart, Splral progression of feed rateand thread error alters average lead, even though the lead is straight,3 0 1 GEAR TECHNOlOGY

-..'! IL ead to po gru ph y as see n bythree ' traces on a helical geurbobbed at high feed rate

II

I II

Fig, 7 - Tooth topography showing three leadpossibilities IImeasuring probe might "see," Withre ference to Fig. 6 and t he i nt ro d uc ti on of hobthread-to-thread errors La the lead trace, which themeasur.ing probe "sees," funher opporltmily isprovided for incorrect evaluation ofthe lead.Manufacturers who purchase brand new

equipment for hobbing or shaping gears cannotexpect significant improvement in the qual-:ily capabil ity of tile new process over the oldprocess if they do :notimprovetrhe prioreperations and part geometry specificationsinvolved in the blanking of the workpiecesfor the bobber or shaper,Manufacturers who purchase brand new

hobbing machines and shaping machineswith a . specification level of 2.0, tightproduction tolerances, and low piece num-ber qualification samples should not expectth e new rnaehlnery necessarily to givethem a producttvlty improvement. Capa-bility indexes greater than].01 against strin-gent tolerance fields on all gear elementsseverely constrain the gear manufacturingprocess in the name of statistical controlwhen. ill reality, the applicarion of SPC toanalyrical inspection methods may have nofunctional validity. In such cases, for hob-bing and shaping, an application of ccrnmonsense is usuallyaecessary .Acknow'ledgement: Presented at the A,GMAGearMllllU/aCI uring Symposium, April 7-9, J 99 J , Chicaga, IL and at tin SME Gear Clinic. Reprin.ledwith permission

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Exciting news for thegear industry ...

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double flank grindirproductivity with

BHS-HOFLER geargrinding machines arewidely acknowledged asthe' most accurate geargtmders in the world.

Now - BHS-HO'IFLERintroduced the impro-ved double flank grin-ding m,ethod'" to . com-pete even with

'"D'ouble flank grin-ding means: simahaneous grinding oftWlJ' opposite toothflanks with bothsides oj a rigid-racktype formed grin-ding wheel in mesh.It is still themost accurategeneratingmethod and it;srUJ'W fasterthan formgrinding ..

I Ihe fastest grindin!gmachines on the mali-k e t o And the best: BHS-H()FLER machines ar estill the most versatileones, You can grind anygear with almost notool eost, using stan-dard inexpensivegrin-ding wheels, ausomati-eelly dressed to size onthe grinder and ofcourse with our CNC-dresser,

A BHS-HO'IFLERmachine will grind yourgears just when youneed them with very

inexpensive wheels un-like form grindingwheels. Profile or leadmodlflcatinnsare noproblem. Every BHS-HOFLiBR is capabte ofgrinding even the mostcemplicated toothforms 'to meet your pre-sent and future require-ments.

PRODUCTIVITYHIVe yo- ,enl checkedy o,u reC .-u p tl.m ,es ?ou are losing bun-dredsof hours of valua-Me production timewith the grindingmachine idle while youare setting up the gear

and fixture onthe macbine.Now our newlydeveloped pre-ctsten panet.:loadlnll sys,te:moffers unbea-table produc-

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30-50 0/0:gear grinding

tivwtyl Our pallet setupstations win keep yourgrinders, busy. Muchfaster change-ever rime.All unproducsive setuptime is done outsidethe machine where itbelnngs while your grin-ders grind gears hourafter hour - uninterrup-ted. Twenty four hoursa day? No problem, pal-lets can be Winedup forthe 2nd or 3rd shiftoperation.

SUPPORTTo get the maximum,uoducti.vity from yourBHS-HOF.LER. we nowoffera training pro-gram for your 'opera-tors. EXIl'erieo.cedinstructors let youbenefit from their life-long obtained know-how. Our computer pro-gram. is available to cal-culate grinding times,raachine set-up dataand other valuable para-meters.

Even the best machinesneed service and partsfrom time to time. OUIfactory-trained serviceengtneers are availablefrom .OHS-HOFLERCORP., New Jersey.In addition to' spareparts we stock grindingwheels and otherperishables in our U.S.facility,.For more Information,call or write toOMS-HOFLER CORP.P.O.Box]27Sky Manor RoadPittstown,NJ 08867Te l.: 9 08 -9 96 -6 9'2 2Fa x: 9 08, - 996- 6977

We will be more thanhappy to arrange ademonstration. in yourarea at one of OUI T U .S.customers or to olga-nize your trip and visitto .8HSHOFLER inBttllagen, Germany,

system.

You are producing har-dened and ground ge-ars. A product with abright future becausemore and more gearsare ground, Out like inevery competition onlythe best will survive.The gear grinding ope-ration in your companyis probably the mostimportant one becausethis is where your Damego,e on your product..8HS-HOFLER state ofthe art gear grindingmacbines send signalsto your customers thatyour ,company is a Iea-del' io. its field becauseyou are capable of pro-dudng the highest qua-lity products, Get thebest, contact us and wewill put you in the com-pany of tbe most sue-cessfulgear manufactu-rers in the world. Let'sdo it together.

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. 'BHS-HOFLER salesagents In

H{estem States:AMERICAN MACHINERYAND ENGINEERING CORPORATIONP.O.8.2]57Mission Viejo, CA 92690'Tel.: 714-586-20'0'0'Ask for Ron LuebkeIndiana. Illinois, Wisconsin, .1owa.Minnesota:lRM & ASSOC., INC.5633 East State StreetRockford, IL 6110'8Tel.: 815-3'97-7557Ask for lim Mattox or Ma.rk BitelerNew England States:LYND.FARQUHAR CO.East Point Crossing176 East Main StreetWestborough, Mass, 0'15811706Tet: 50'8-898-9494Ask for Howard Rich or Rob Smith

the USA:

E-"ennsylva.nia', Mew Jersey, Maryland. CaroUn.a:H'OLCO INC ..8 Lindenwold TerraceAmbler, PA 1'9'002Tel.: 215-.283-'0156Ask fur Emil or Marc ContiW-Pennsy.lv.ania. Michigan. Ohio. Kentucky .Virginia:I. LEE HACKETT C'OMPANY23550 Haggerty RoadFarmington, Michigan 48335-2636TeL.: 313-478-0200Ask for J. Lee Juett or John McCartney

8HS-Hofler Maschinenbau GmbHIndustrlestralse 19 D-75O'5EttJingen 7 . GermanyTel. 0 ' 72 43 19910 . Telex 782907Telefax 072 431 '9 's n 65

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Fu l l -L o ad Tes t i n g o fL a r g e G ea r b o x esU s in g C lo s ed -L o o pP o w e r C i r c u la t i o n

R . I B . F r o s tU n i v e r s i t y o f IN ' e w S ' o u th W a l l e s . K e n s i n g t o n , A u s t r a H a

' l R . C ' r o s sJ 'o h n W e ' l s b Ply. L t d . M ' e l b o u r n e . A u s t r , a ' ii a

Summary: Thi .method of testing large gear-boxes or, indeed. any power transmission ele-ment. has numerous advantages, and offers ' thepossibility of large avings in time. energy, andplant. if the overall. situation is conducive to itsuse. This, u u ally requires that several such unitsneed to be tested. an d that they can be conve-niently connected toeach other in such a way asto form a clo ed-loop drive train ..No power ink (a)is required. and the drive input system has onlyto m ake up power losses. The level of circulatingpower i controlled by the torque, which iapplied stat jcaUy during rotation,and the drivepeed. Principles. advantage, and limitations are (b)described. together witb. recent experiences inthe only known large-scale usage of this tech-nique in Australia,

IntroductionFull-load testing of large gearboxes and other

power tran mission modules or components hastraditionally been carried out. with 'Ille tesungdrive train arranged in .3 . schematically linear OTopen manner, a hown in fig. la o This necessi-tates the use of a power source and a power sink.or brake, each with .3 . capacity at lea t equal 10that ofthe required test further. all energywhich passes through the gearboxunder test,which can. be considerable. is wasted inlhe ink.This 13 t factosiscornpounded unumerous unitsneed to be tested, Iflhe rated power of thegearbox under test is large.and the output speedis low, the torque at the sink can be inconve-

oiently mas ive, unless further supplementarygearing is provided ..One way of doing this, ofC~lU" e, is to test two gearboxes simuttaneouslyin series, as shown in Fig. 1 . 0 . . This, however.does nothingto avoid the necessity fora largesource and sink.

I P o w e r l l 1 GearSource III B oxUnder I ,Power IestI I

Sink

l P , o w e r l Ie , I IPo;-'t 'sr I IIrst I S ~ : ~ d ,ource I Gear I Sink IB ox I B o xUnderIUnderTest I Test I

F ig . ~ - T he tr ad itio na l, schemal:icaJI.y o pe n a rra ng em en t o f g earb ox te st rig s: (0)the .implesl arrangement; (b ) a tandem anangememt which tests two gearboxes im l ll lnneo li sl y and wh ich avo id s 8.ma ss iv e to rq ue a t a lo w s pe ed al th e power s ink.The above situation can be markedly im.-

proved by the use of a closed-loop arrangementof the test drive train. Such an arrangementallows the return to the test system ofthe outputpower from each gearbox under te st, s o th at. no power sink is required;.' the power ource only has to provide make-

lip power equal to the sum of system losses:.'several gearboxes are 'tested simultaneously.Obviously. large savings can accrue from the

avoidance of the necessity for iii power sink and!

I R . B . F r a s 1i s S en io r L e c/ ur er .S choo l 01Mechan ica l&. Industrial Engineer-i nB . Univers it y olNewS o ul h Wa le s,T . R . C r o s sis MalUIging Director.John Wt'/~h ,Pty. LId. infIilelbouf"1!l!. Australia.

SEPTE,IIBERIQCTQ!lER 18111 3 5

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nom thelarge reduction m 'the required capacit.yo f th e p ow er source. Ifnumerous u nits need to b etested, large savings in time and energy arepossible.Disadvantages or Iirmtancas on the use of

such a test method are that OO I1 -b ac kd ri vin g g ea rb ox es . s uc ha s h ig h-s ar in

worm drives, cannot. be tested in this manner; a somewhat larger floor area is required for

the test. setup; th e pow er level in each gearbox. in a particu-

la r setup' win be s li gh t ly d if fe re nt due to lossesaround die drive train loop;.the method isbest suited to situations where

at least as many gearboxe need to be tested asare required to make up the drive 'train loop;

if the number 'of units to . be tested is not. anintegral multiple of die ollmber required to makeu p th e loop, some will need to undergo two teststo allow fonnation ofthe final loop at the end ofthe series of tests.While such multiple simultaneous testing is

not uncommon in Europe. it has not been used toany great extent in AllJstralia.

The Drive Traio. LoopThis consists of several of the l imits to be

tested, coupling shafts, and three other compon ents : a m otion in pu t dnve,a torque application,coupling, and a torque transducer.Such a loop can be achieved in several conve-nient ways ..I ft h e g ea rb o xe s a re p ar al le l- sh a ft ed ,two can be coupled as shown in Fig. 2; if theyinvolve shafts at right angles, e.g., as wwth bevel

GEA .RIB O X 1 1

II

~,i~ 10....- _DR I VEIN 'PUTFig. 2 - A elo .ed-loop arrangement rorr testing two parallel-shafted gearboxessimultaneously and IJtiJizingcirculating power, thereby avoiding thenecessity fora ' powe r sink., 3 6 1 GEAR TECHNOLOGY

input stages, chen four can be coupled as shownin Fig, 3. For generality, and because of recentexperience with such a ' erup, the remainder ofthis article is written as relating to a setup lISshown in Fig. 3.The three additional. components referred to

above can be incorporated in any convenientmanner or location in t he l oo p, The drive inputcan be incorporated ina coupling shaft as a 'beltor chain drive or as a separate gearbox with adouble-ended output shaft, or it can be attacheddirectly to a shan extension on one oflhe unitsunder test, If one ti s available. Alternatively. ifthe motor speed corresponds to th e s peed 0 1 thehigh- peed shafts, and the motor has a double-ended shaft, i t ca n be incorporated directly inone of the high-speed shaft lines, The torqueapplication coupling is a device which join apair o f ad jacen t. shan ends and which applieequal an d opposite torques to them whiletheyare borh rotating. and in the presence of somedegree uf relative rctatian between them, It maybe thought of in practice as a hydraulic motor,supplied and drained by two lines via a rotatablehydrauli.c coupling, with :its shaft connected toone of the tw o s ha ft ends referred to above. andits body connected to the other.

The Action . o f the Test Rig'This is best described by considering tbe rig atrest while the torque application coupling isloaded by the application of hydraulic pressure.The whole drive train loop is thereby loadedtorsionally so thateach section of it. being intors.ionaI equilibrium, has equal and oppositetor1lues at its two ends: i.e., an actioa and areaction ..If the motion input :isnow started. thewhole drive train loop w:iUrotate in the directionin wh ich it is driven. Fora particular loop 'oc-tion, the applied torque and the rotation will bein . the same direction at one end, where powerwi IIbe entering thadoop sec tion, and illoppos itedirections atthe other end, where power will be~eavinglh3!t loop section. This applies to eachloop section, so that power eirculaees continu-ously around the drive train loop in a dieecticnwhich is determined by the combinanon of thedirectioas of the drive rotation and the torqueapplication,The level of circulating power is,detennined

by the combination of the speed of the driverotation and the level of the torque application.

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where T l is th e efficiency of each ind iv idua l Fig .], - Similar t oF i g . 2 . b u t to su i t four r igh t -angle-dr ivegearboxc . Power flowsgearbox . 0 th at th e to ta l p ow er [0 is giv en by and losses are h ew n,

boxes, C le arly . la rg e av in gs io in stalle d c ap ac -ity . tim e and energ y can b e realized , prov id edt he ov e rl oa d OR som e u nits can be to le ra te d fo rth e duration of th e tes t. Th is overload i,ofc ou rs e. s ig nif ic an tly r ed u ce d if P I' P 2' orP 3 canb e a gre ed upon as th e pow er level for th e test,r ath er th a n P 4'

C on sid era tio n n ee ds to b e g iv en to th e "h an d-in g" o f g ea rb ox e an d th e re su ltin g c om pa tib il-ily o f rota tionaround th e d riv e train loop. R e-gard le o f th is . however, it i nece arily trueth at o ne d iagon ally oppo ire p a'ir of b oxes w illb e o p era tin g in th e c hema tic aU y fo rw ard (p ow er-flow ) sense as ' peed reducers , bearing on theforw ard flank s o f th e tee th , wh ile th e oth erd iagonally opposite pa ir are operating in th es ch em a tic ally b ac kw ard s en se a s s pe ed in cre as -er , b earin g on th e rear flIank s. P D r s pir al b e ve lgearing th e d ifference in geom etry and forcelevels b etw een th ese two ca e are lgm fican t,W hether th is is seen as a p rob lem . a in th en ece ss ity to p ro ve e very b ox in e very m od e, o r asa ll,o pp ortu nity w hereb y eac h o f th ese tw o. c a escan b e d em on trated sim ultaneo us ly , d epen dsIOnth e way in wnich test requirements a re w rit-ten . A t m ost, h ow ev er, th is prob lem w ould onlyin vo lv e a re ve rs al o fro ta tio n a nd /o r to rq ue in th e, r une setu p o nce tes ting is un der w ay ,R ecent E xperience W ith C losed -L oop T es tingJohn W elsh P ly . L td . of Me lb o ur ne r ec en tlyupplied 2~ gearboxes , each ra ted a t 610 kW ,\485 RPM input speed .. I7.76: \ redaction ratiowith a sp iral bev el input s tage and a helical

W ith th e excep tion of th e Iosse due 1 1 0 th ei ne ff ic ie n ci es l in the gearboxe power does notle av e th e d riv e train loop; therefore, it doe ' 1 1 1 0 1ne d to b e p ro vid ed b y th e d riv e in pu t, except torth e losses, re ga rd le ss o f th e level ofthe circular-in g p owe r.P ow er flow s and 1 1 0 ses are sh ow n in F ig ..3 . If

P I is th e input power to th e gearbox IOn th e"downstream" sideof th e d rive inpu t (in th epo wer-flow en e) and P :s is th e pow er d eliv eredto th e d riv e in pu t by th ea djac en t g ea rb ox o n th e"up ITeam " ide , th en

T he input p ow er frac tion, w hich is th e ratio o finput p ow er re qu ire d w h en 'l.Is in ga c lo e d-lo oprig to th aI. required w hen u sin g a rig o f th e ty pesh ow n in Fig .. I, w here inpu t pow er m ust equa ltes t pow er, is g iven b y

4P. . I -11f = mpul =- (3)p P 1 ' \ 34

w here P4, w hich is th e low es t inp ut pow er lev el[0a ny g ea rb ox in th e [001'. is taken robe th ea gree d p ow er le vel fo r 'th e tes t. T his a gree men tcould be m ad e d ifferently . of course . in w hichcase , f w ill b e d efin ed d iffe ren tly . b ut th is willpma k e l ittle d if fe re nc e tD f .pT he in pu t e ne rg y fra ctio n :fo r te stin g a s erie s o fgear boxe in th is w ay, ra th er th an a in Fig, 1 , i sg iven by

f 1 ~ 1 1 4f = = .. . . : : : : - - (4)E - c - 3N Nilw here N is th e num ber of gearbox units tes teds im a lto ne ou sly . .In th e s itu atio n c on sid e re d h e re .N=4.S im ilarly . th e o ve rlo ad fac to r o n G ea rb ox I, in

o rder to ach ieve P4 in to G earbox 4 , is giv en by

F ig ,4 h ow s \la \l.1 eso f fpi fE ' and Fo fm a rangeof T \ w hich is re alis tic t:o r a larg e ra ng e o f g ea r-

(5)

P' + (1-'1) P'l OSS2 2

Pi- (1-11) PLoss! 1

SE PT E !.IBE R IO cr e B E R 1991 3 7

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1 . . 15 , ,..---""""T----,~----,.---.------,I , 0 5I I

F~g.4 - Variation of energy fraction fE ' power fraction fp' and overload factorFo far a ra ng e o f e ffic ie nc y .:1 f I l . for th e se tu p sh ow n in Fig. 3 .

output stage, for coal conveyor drives. Thesewere te ted four-at-a-time in an arrangementsimilar to that shown in Fig. 3, at 50% of fulllo ad a nd then at H X J% of full load, in each caseuntil temperature equilibrium was reachedand thereafter to allow noise measurementsto be taken.Drive input. was v ia a multiple V-belt drive

of the appropriate ratio from an inductionmotor rated at 220 kWal 960. RPM. onto oneof the high-speed shafts connecting the gear-boxes ..This haft also contained the torqueapplication coupling, which was a propri-etary item, model VM2-4000-100 fromGlyco in Germany. It provided two activehydraulic chambers. in each direction to fa-cilitate tile production of a large torque froma compact design, and thereby provided atotal relative rotation of on I.)!'WO. The elas-tic torsional deflection around the drive !rainloop at 1.15% of futl-Iead torque, 9

E, was

calculated to be approximately 31.so of rela-tive rotation at the adjacent shaft ends wherethe torque application coupling was to belocated and tile backlash in the gearing, ,(JSL'was estimated to be approximately 5 . 5" at thisloeation. For loading in both direction, thisrequired a total relative rotation of the torque Acknowledgemen't: Th.is aniele was originallyapplication coupling of presented at The }n.r/jlmiO'n 0 '1 Engineers ..AUSlrQ-

1 .3 I--~-.,...j-~'r-I~--+--""""""---il 0 .3I~ ~~~

1. 2 I----II---~---"'rl"'-'---t__--t- 02

L- ~L- ~L- ~L- ~~~o1091 . 0 96

1)098

appro imarely 31.5" for angular assemblyof the flanges of this coupling, which. it wasanticipated, would be assembled last in thedrive train loop with its mating flanges onthe adjacent coupl ing shaft ends. In tile event,however, it was found that the torque trans-ducer had sufficient holes in its flanges toallow convenient final closure and connec-tion 'of the drive train loop at its flanges.with the torque application coupling ini-tiaUy set .0 that it had approximately 7 S O t l ofits stroke available il l 'Ihe reqaired directionof testing.The Lebow 1641- lOOK torque transducer

was located ill the other high-speed shaft.In eachinstance of testing, the motor

driving the rig was tarted while the torqueapplication coupling was ubject to a smallrequired minimum pressure of approximately5 bar. This gave rise to the necessity toovercome some degree of initial stiction inthe lightly torsionally pre-loaded rig. Thiwas nota real problem, however, and oncethe rig broke the stiction and started tomove,it ran very freely. The.hydraulic pressure tothe torque application coupling was thenprogressively increa ed, thereby increasingthe circulating power Ievel, the losses. lindthe motor load, until the required readingwas achieved en the torque meter. Thi read-ing of course, had to be calculated specifi-cally in view of the pcsition 1 . 1 1 Ihe drivetrain loop occupied by the torque transducer.The rig was then run as required for thetesting procedure. In all cases the rig be-haved in a stable manner and the testingproceeded without problems.

ConcilUlsi.onSlmaltaneous res ting of mulltiple gearboxesusing a elosed-looptest rig arramgementis a veryconvenient and co t-effective testing methodwhere the conditions favoring such a method. asoutlined in the introduction. are satisfied. Onsuch occasions. (he authors recommend con sid-eration of this method. I.

lia, Filth Intemattona! Conference 0/1 Manufac-(6 ) turing Engineering, July 1113, 1990.

W,ollongong, NSW, Australia. Reprinted withwhich was within its range and which left permission., 3 8 , GEAR TECHNOLQGV

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