0409_gearsolutions

A HArd TurnToward EfficiEncy

Site Safety tooth tipS

Q&a: RobeRt o’ConnoRJ. Schneeberger Corp.

Company pRofile: Advanced Machine &Engineering Co.

APRIL 2009

WorkHolding ThaT works

PrinciPles of workholding: iii

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APRIL 2009 �

April 2009

45MACHINES 48MARKETPLACE �1ADVERTISERINDEX

VOLUME 7 NO. 73

p. 40

p. 32

p. 22

p. 20

Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: Send address changes to Gear Solutions magazine, P.O. Box 1210 Pelham AL 35124. Publications mail agreement No. 41395015 return undeliverable Canadian addresses to P.O. Box 503 RPO West Beaver Creek Richmond Hill, ON L4B4R6. Copyright®© 2006 by Media Solutions, Inc. All rights reserved.

DEPARTMENTS 8

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INduStryNEWSNew products, trends and developments in the gear-manufacturing industry.

SItESAFETY Terry McDonalDEquipment must be designed to accomplish the task at hand, of course, but it’s important that operator safety be taken into consideration as well.

tootHTIPS WilliaM crosherGear-drive inspection reveals the effects of residual stresses on face contact in high-speed gear units. This installment explores the issue and provides solutions.

Q&A WiTh roberT o’connor, sales ManagerJ. Schneeberger Corporation

CoMpANyPROFILE ADVAnCED MAChInE & EngInEERIng Co.by russ WillcuTTWhether it’s tombstones, mechanical clamp-force cylinders, or self-aligning fixture elements, this company has the answers to your workholding challenges.

A HArd turN towArd EffICIENCyby chrisTer richTWhile grinding is the traditional finishing technique for hardened steel gears, hard part turning provides quite a few benefits that may improve your process, and your product.

prINCIplES of workHoldINg: pArt IIIby Juergen KeMpf anD TiM peTerson, cMfgTIn the third—and final—installment in a multi-part series on workholding, Toolink Engineering and König-mtm discuss inspection, special fixtures, and more.

workHoldINg tHAt workSby ann peTTiboneSmart manufacturers can maximize their workholding investment by learning how to use these devices efficiently and to the full extent of their capacity.

FEATURES20

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INDUSTRY RESOURCES

over the years we’ve developed quite a few innovative, multi-part features with the help of our friends in all sectors of the gear manufacturing industry. i can think back to a number of series that have allowed the authors to really stretch their intellectual legs and explore top-ics of their choosing in depth and detail. This is the same philosophy behind our columns, in which authors from various fields range beyond the confines of a single article and share their expertise in installments, over many issues. Terry McDonald, author of “site safety,” has been with us from the very beginning, for instance, and William crosher has been mak-ing his contribution in “Tooth Tips” for many years, as well. you will find just such an instance in this issue of the magazine, in which Tim peterson, cMfgT—engineering and sales man-ager for Toolink engineering—and Juergen Kempf of König-mtm conclude their three-part series on workholding. all three articles are available for download on our Web site [www.gearsolutions.com] and together represent a very nice education on aspects of workholding that are sure to help you streamline your manufacturing operation. The reason i mention this is because i’d like to make clear that, just as we’re always interested in hearing your story ideas for single articles, we’re also open to teaming up with you on more ambitious projects that will be of benefit to our readers, and to the gear manufacturing industry at large.

in addition to the Toolink/König article “The principles of Workholding: part iii,” longtime contributor ann pettibone—ceo of the Drewco corp.—has penned “Workholding that Works,” in which she shares tips on how to maximize your workholding investment by learn-ing how to use these devices fully and efficiently. it’s a pleasure to welcome Drewco back to our pages after their initial contribution to the fourth issue of the magazine, in July of 2003, and an opinion column the following april. you will also enjoy reading “a hard Turn Toward efficiency” by christer richt, who is with sandvik coromant, in which he discusses how developments in machinery, component materials, and hardening processes, among other improvements, have made the metal cutting of hardened parts an attractive alternative to grinding. William crosher discusses how gear-drive inspection reveals the effects of residual stresses on face contact in high-speed gear units in this month’s installment of “Tooth Tips,” and Terry McDonald points out the importance of current shop-floor signage and how opera-tor-safety features should be built into new machine designs in “site safety.” our company profile this month is the advanced Machine & engineering co. (aMe)—many thanks to alvin goellner and Doug robinson for taking the time to speak with me—and robert o’connor, sales manager for the J. schneeberger corp., is our Q&a subject.

in closing, we will soon be launching Wind Systems magazine, as you know, and one thing we’ve noticed in developing this project is how many of our longtime friends in gear manu-facturing are involved in that industry as well. if you’re one of those companies and plan to attend the american Wind energy association’s WinDpoWer 2009 conference and exhibi-tion in chicago, please stop by to see us at booth #2516, where we’ll be introducing Wind Systems. The event will be help May 4-7 at the Mccormick place convention center, and you can learn more by going to www.windpowerexpo.org. hope to see you there!

Russ Willcutt, editorGear Solutions magazine

[email protected](800) 366-2185

� gearsolutions.com

No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, record-ing, 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 web site, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to [email protected].

Published by Media solutions, inc.P. o. Box 1987 • PElham, al 35124

(800) 366-2185 • (800) 380-1580 fax

CoNtrIbutINg wrItErSWilliaM P. crosher

Juergen KeMPfterry Mcdonald

tiM Peterson, cMfgtann Pettibonechrister richt

David C. CooperPuBlishEr

Chad MorrisonassociaTE PuBlishEr

EDITORLETTErFrom THE

Dav id C . C o operPrEsidEnT

C had Mor r i s on VicE PrEsidEnT

Ter e sa Ha l loPEraTions

EdItorIAlRuss Willcutt

EdiTor

SAlESBrad Whisenant

naTional salEs managEr

CIrCulAtIoNTeresa Hall

managEr

Jamie WillettassisTanT

Kassie HugheyassisTanT

ArtJeremy AllenarT dirEcTor

Michele HallgraPhic dEsignEr

8 gearsolutions.com

INDUSTRYNEWS

Raycar Gear & Machine Celebrates its 20th Anniversaryover the past 20 years raycar gear & Machine’s accomplishments have included more than tripling its qualified manpower and manufacturing space, continuously increasing its productivity and capabilities by adding state of the art cnc gear equipment, and maintaining a high level of customer satisfaction. The company is iso9001:2000 and as9100:2004 certified, and it is always focused on continued quality improvement.

in the spring of 2008 raycar added its third hofler helix cnc gear grinder. With three gear grinders the company has the capacity to grind practically any tooth pro-file including crown, taper, and tip relief, and with nearly any imaginable modification. raycar consistently achieves and exceeds agMa class 12 quality gears, and it has also recently added a gleason sigma 7 gear analyzer, resulting in increased gear-checking capabilities. The summer of that same year saw the purchase of a Mitsubishi gD50 cnc hobbing machine, increasing productivity even further by ramping up feed rates on all axes along with speedier table and spindle rotational speeds. This machine modernizes raycar’s hobbing capabilities by allowing for larger gears to be produced while decreas-ing cycle times. The combination of these machines, along with experienced operators, allows raycar to excel in manufacturing precise, high-quality gears.

raycar gear & Machine celebrates two decades of success by continuing to provide the quality products and excellent service its customers have come to expect. To learn more call (815) 874-3948, send e-mail to [email protected], or visit online at [www.raycargear.com].

Proprietary Grinding Technology from Obergoberg industries offers the world’s most advanced grinding technology with the Molecular Decomposition process™ (MDp™). Developed for the most efficient removal or cutting of any conductive material, MDp uses an electrochemical action and an abra-sive wheel to achieve a surface finish of less than 1 ra and precision toler-ances held to ± 0.0002", all without generating heat. The process is ideal for use with consumer or industrial products where surface finish and dimensional stability are imperative. MDp is also suitable for applications requiring a surface free of micro cracks and fissures or other highly polished weight bearing and articulating surfaces. gentle enough to grind thin-walled components without damage or distortion, MDp works well with tubing, rapid cut-off needs, and grinding of complex features in exotic metals, including nitinol.

Companies wishing to submit materials for inclusion in Industry News should contact Editor Russ Willcutt at [email protected] accompanied by color images will be given first consideration.

New Products, Trends, Services, and Developments

“no other method of grinding or cut-ting can compare in performance with its speed, precision, repeatable accu-racy, and clean operation,” says Joe Deangelo, director of technical develop-ment. “MDp can even eliminate second-ary operations such as electro polishing, micro blasting, and deburring without generating thermals or causing internal stress and distortion in the material. its applications are endless.”

During MDp an electric current flows between the negatively charged abra-sive wheel and the positively charged workpiece through an environmentally friendly electrolyte (saline) solution. a decomposing action occurs, causing the material surface to oxidize. This oxidized surface is then removed by the spe-cially formulated abrasives in the wheel, exposing more material and repeating the cycle. MDp cuts conductive materi-als 80 percent faster than conventional methods and is especially effective on super-alloys and exotic metals. it can be used with the following con-ductive materials: aluminum, beryllium, cobalt chrome, copper, inconel, iridium, molybdenum, nickel, nitinol, platinum, rhenium, single crystal alloys, stain-less steel, titanium, titanium carbide, tungsten carbide, zirconium, and other conductive ceramics and plastics.

after working closely with compositron corporation for over five years to further develop and refine the process, oberg acquired the MDp technology and the full consumable products line of Voltron™ grinding wheels and electrolyte in July 2007. Voltron grinding wheels and elec-trolytic solution continue to be manufac-tured and developed at oberg’s sarver, pennsylvania, campus to fit a variety of cutting and grinding applications. To learn more go to [www.oberg.com].

New Gear Brochure from DSM Engineering PlasticsDsM engineering plastics announces the release of its new gear brochure, which highlights the use of stanyl polyamide 46

10 gearsolutions.com

for high-temperature, high-torque transmit-ting applications. for oeMs and manufac-turers looking for high performance, safety, and durability in motor management gears, this brochure highlights material proven solutions for gear applications that deliver mechanical and constant performance at high temperature, excellent tribological behavior, and high fatigue resistance.

DsM engineering plastics is a busi-ness group in the performance materials cluster of DsM, with approximately 1,550 employees worldwide. it is one of the world’s leading suppliers of engineering thermoplastics, offering a broad portfolio of high performance products including stanyl® high performance polyamide and akulon® 6 and 66 polyamides, arnitel®

Tpc, arnite® pbT and peT polyesters, Xantar® polycarbonate, yparex® extrud-able adhesive resins. These materials are used in technical components for electrical appliances, electronic equip-ment and cars, and in barrier packaging films, as well as in many mechanical and extrusion applications. stanyl is the global market leader in high heat polyamides. To learn more please visit [www.dsmep.com].

royal DsM n.V. creates innovative products and services in life and materi-als sciences that contribute to the quality of life. DsM’s products and services are used globally in a wide range of markets and applications, supporting a healthier, more sustainable, and more enjoyable way of life. end markets include human and animal nutrition and health, personal care, pharmaceuticals, automotive, coat-ings and paint, electrics and electron-ics, life protection, and housing. DsM employs some 23,000 people worldwide. The company is headquartered in the netherlands, with locations on five con-tinents. a pDf of the brochure can be downloaded at [www.stanyl.com]. also go to [www.dsm.com].

OSU GearLab Presents Basic and Advanced Gear Noise Short CoursesThe gear and power Transmission research laboratory (gearlab) at The ohio state university announces two upcoming educational opportunities: the basic and the advanced gear noise short courses. Details are as follows:

• basic gear noise short course: June 10-12, 2009This course has been offered for over 30 years and is considered extremely valuable for gear designers and noise specialists who encounter gear noise and transmission design problems. attendees will learn how to design gears to minimize the major excita-tions of gear noise: transmission error, dynamic friction forces, and shuttling forces. fundamentals of gear noise gen-eration and gear noise measurement will be covered along with topics on

APRIL 2009 11

gear rattle, transmission dynamics, and housing acoustics. This course includes extensive demonstrations of specialized gear analysis software in addition to the demonstrations of many ohio state gear test rigs. a unique feature of the course is the interactive workshop session that invites attendees to discuss their specific gear and transmission noise concerns. cost: $1,590

• advanced gear noise short course:

June 15-16, 2009This advanced session is an extension of the basic course and will be taught through lectures on selected topics coupled with a series of hands-on workshops. based upon their interests the attendees may select from the fol-lowing topics: analytical and comput-er modeling (prediction of gear whine excitations, general system dynamics, bearing/casing dynamics, gear rattle models); and experimental and compu-tational approaches (modal analysis of casings, acoustic radiation, advanced signal processing, sound quality analy-sis, transmission error measurement). cost: $1,090

To learn more, or to enroll, call Jonny harianto at (614) 688-3952 or fax to (614) 292-3163. send e-mail to [email protected], or go online to [www.gearlab.org].

Boeing Achieves Major Environmental Certification Goalboeing has announced that all of its major manufacturing facilities received the internationally recognized iso 14001 environmental certification by the end of 2008, marking achievement of one of the company’s most significant environmen-tal goals. certification is a global bench-mark of an organization’s commitment to understand and continually improve its environmental performance.

“We recognized many areas of excel-lence at boeing, from employee involve-ment programs to recycling efforts, in one of the most aggressive iso 14001 certification efforts we've seen,” says sidney Vianna, director of aviation, space

& Defense services for independent audi-tors Det norske Veritas, an accredited certification body of quality, environmen-tal, and safety management systems. “congratulations to boeing on this sig-nificant accomplishment. We look forward to our ongoing partnership in continual environmental improvement.”

The following boeing sites certified

during 2008 were commended for their environmental performance with more than 80 positive noteworthy efforts and no major nonconformances:

•alabama: huntsville•arizona: Mesa• australia: bankstown, fishermans bend• california: el segundo, long beach,


seal beach, sylmar, Taft, Torrance•canada: Winnipeg•florida: Kennedy space center•Missouri: st. louis, st. charles •pennsylvania: philadelphia•Texas: san antonio•utah: salt lake city• Washington: auburn, frederickson, renton, and north boeing field,

integrated Defense systems sites in puget sound

“as a responsible corporate citizen and neighbor we are focused on reducing energy use, greenhouse gas emissions, pollution, and waste at our facilities,” says Mary armstrong, boeing vice presi-dent, environment, health and safety.

“certification is a tremendous achieve-ment by our employees, ensuring that boeing products, from our super-efficient commercial airplanes to our military air-craft, satellites, and world record-holding solar cells, are manufactured in facilities that conform to the iso 14001 standard of environmental performance.”

facilities in exmouth, australia; everett, Wash.; and portland, ore. had previously achieved iso 14001 certification. boeing is committed to pioneering environmen-tally progressive products and services and reducing its environmental footprint. some other highlights of its 2008 work include the establishment of aggressive targets to improve by 25 percent greenhouse gas emissions intensity, energy efficiency, and recycling rates at its major manufacturing facilities by 2012, with a similar goal for hazardous waste reduction. The company also conducted the world’s first series of test flights powered in part by sustain-able biofuels, in collaboration with air new Zealand, continental airlines, and Japan airlines. boeing is focused on research for advanced generations of sustainable biofuels using biomass that do not com-pete with food crops or water resources, and it released an environmental report detailing its performance, strategy, and actions to reduce its environmental foot-print and lead the aerospace industry with environmentally progressive products and services. in addition, it conducted the world’s first straight-and-level flight of a manned airplane powered only by a fuel-cell, led by Madrid-based boeing research & Technology europe—the research may benefit secondary aircraft system power use—and it delivered world-record holding solar cells by boeing subsidiary spectrolab, inc., to an australian customer to power a 154MW power station. To learn more go to [www.boeing.com].

New Fixturing CD from Advanced Machine & Engineeringadvanced Machine & engineering co. (aMe) announces its newly updated fixturing solutions cD. included on the cD is a brief fixturing overview and video along with detailed information about aMe’s fixturing products and services, links to complete

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APRIL 2009 13

online catalogs, caD models, and a com-pany overview and video, plus contact infor-mation. new additions to the cD include new fixturing products such as dedicated manual fixturing and Jakob antriebstechnik clamps with new caD models, plus an iso conversion calculator and measurement unit convertor.

aMe can design and build amrok® ready-to-use dedicated manual fixtures from the ground up for horizontal and vertical machining centers and other cnc machin-ery. Dedicated manual fixtures offer a variety of benefits for customers, including: reduced machine setup and cycle times; improved operator safety; improved toler-ances resulting from the use of a single fixture as opposed to multiple fixtures; and reduced workpiece handling, which in turn can result in increased part production.

several new workholding clamping prod-ucts from Jakob antriebstechnik offer sim-ple manual operation, high clamping forces, and high operation safety. The variety of clamps, nuts, springs, and screws can be used to clamp workpieces and tools or to clamp down closing lids of tanks and enclo-sures. They can also be used in presses, punches, machine tools, jigs, and fixtures.

advanced Machine & engineering—locat-ed in rockford, illinois, and profiled in this issue of Gear Solutions magazine—is a global manufacturer and distributor of pre-cision machine components, fluid power components, fixturing/workholding, power drawbar and spindle interface compo-nents, and saw machines and blades. The company also designs and builds special machines for a variety of industries and provides machine rebuilding, retrofitting, and contract manufacturing services. aMe has partners and customers around the world and across the united states. To learn more go to [www.ame.com].

UV Lamp for Industrial Leak Detection from SpectronicsThe spectronics corporation has intro-duced the powerful spectroline® TriTan™ 365, a multi-leD, broad-beam uV leak detection lamp. When used with spectroline fluorescent dyes it pinpoints fluid leaks in a wide range of industrial systems such as hydraulic equipment, compres-

sors, engines, gearboxes, fuel systems, and more.

The lamp features three ultra-high inten-sity uV leDs for fluorescent leak detec-tion, plus a white light leD for general component inspection. its broad-beam

profile provides extra-wide area coverage, while its compact head gets into cramped areas larger lamps can’t reach. it has an inspection range of 20 feet (6.1 m) or more. a built-in fan keeps the leDs cool, providing optimum light output during extended use.

The TriTan 365 is extremely compact and lightweight, weighing just 16 ounces

(454 g). a convenient three-way rocker switch allows easy control of the light sources and a lightweight, angled lamp body ensures fatigue-free inspections. instant-on operation allows the lamp to reach full intensity immediately. it has an 8-foot (2.4 m) power cord with an ac plug and is available in 120V, 230V, 240V, and 100V models. also available is the TriTan™ 365M portable, battery-operated ac/Dc lamp kit. along with the TriTan lamp it has a rechargeable niMh battery pack with an adjustable shoulder strap and belt loop, ac cord set, smart ac charger, and uV-absorbing glasses, all packed in a padded carrying case. for more information call (516) 333-4840 or go to [www.spectroline.com].

Fanless Panel PCs from Maple SystemsMaple systems, a leading manufacturer of industrial operator interface products, has announced the release of three new additions to its gold series family of space-saving panel pcs. These new slimly

contoured 10 inch, 15 inch, and 17 inch fanless models have intel processors and are preloaded with Windows Xp pro. like all in the gold series, these new models are powerful, state of the art, fully func-tional pcs that will run most Windows-based software.

“affordable, yet fortified with computing power, the gold series fanless models are quiet, draw less electricity, produce less heat, and eliminate the problem of particulate matter being drawn into the unit itself—perfect for tightly sealed environments where there is no available air flow,” according to larry st. peter, president. “but just as important, these flat panels are cutting edge pcs that oper-ate most windows software applications, and they offer an affordable functional solution to innumerable manufacturing challenges and computing tasks. and, unlike many of our competitors, the price includes the drive, the high-speed proces-sor, the memory, and the Windows Xp professional operating system.”

With high-resolution, high-brightness TfTs that support 16.7 million (24bit) colors, these innovative gold panel pcs are versatile precision touchscreen inter-faces. in fact, all gold series panel pcs can utilize Windows-compatible industrial applications as well as Maple systems’ optional hMi/scaDa Webstudio software, which is a real-time supervisory control and data acquisition (scaDa) program for creating fully functional media-fortified web-based hMi solutions.

like all members of the gold series family, these three new fanless models are geared to deal with remote data entry, remote monitoring, and scenarios that require support for multiple devices. additionally they are rohs compliant and


APRIL 2009 1�

include a neMa4/ip65 certification. The gold series come with a one year warranty and top-notch customer service and support. for more information call (425) 745-3229 or visit [www.maplesystems.com]. New 12VDC Gearmotors, Motors, and DC Speed Control from Bodine bodine electric company now offers a new selection of 12 volt permanent magnet Dc (pMDc) gearmotors, motors, and a new Dc motor speed control for continuous duty oeM applications. These compact and cost-efficient prod-ucts provide the predictable performance required for low-voltage, battery powered, remote-location, or solar appli-cations. When these gearmotors and controls are used together they provide a complete, single-source motion

control system.The 12 volt pMDc

gearmotors and motors are available in both 24a- and 33a-frame motor sizes. They can be built in combination with most of bodine’s parallel shaft, hollow shaft, or right-angle gearheads, with gear-motor output speeds

from 5.6 to 660 rpm. horsepower extends from 1/50 to 1/8 hp (93 W), and they are able to generate up to 310 lb-in (35 nm) torque. higher output ratings are possible for intermittent duty applications. custom models are avail-able with encoders installed, special output shafts, cords, and customer-specific mounting configurations.

bodine’s new Type WpM–12 VDc speed control is ideal for battery powered, solar powered, and other low-voltage applications that require basic, single-direction speed control. This pulse-width-modulation (pWM) speed control provides cool motor operation, long brush life, lower audi-ble noise, and a wide speed range. Dip-switches allow the control to be easily calibrated for different size motors.

Terry auchstetter, manager for custom product devel-opment, describes how these new low-voltage products can be used. “a customer recently selected our low-volt-age 12VDc products to drive solar powered pumps on pipelines. because these pumps are used in some of the world’s most remote locations, it was critical that the motors did not drain the back-up battery when solar power was not available. by choosing the most efficient wind-ing, gear ratio, and control combination we were able to create a dependable system that is already being used in over 500 systems worldwide.” Visit online at [www.bodine-electric.com].

APRIL 2009 17

so that we do not inadvertently create a hazard? i often notice that flammable materials such as oil storage and propane storage aren’t labeled clearly. also, when lubricants are present, be sure that the proper Material safety Data sheets (MsDs) are on hand. although we have discussed the safety aspects of proper lubrication a number of times in the past, as new products in the lubrication field are introduced—as well as advancements made to new machinery—it would be wise if we reviewed our safety standards concerning lubrication on a regular basis. simply keeping up to date with the MsDs forms is something that has to be reviewed on a regular basis, and if you find there have been changes it is definitely a clue that further review is necessary, and that appropriate labeling posted.

so take a moment to make sure that your signage is up to date and legible. often signs become dirty, torn, or otherwise unreadable in a shop atmosphere, and it behooves us to remedy such situations immediately. not only will it help protect our employees, it will make our insurance carriers happy, and it may even reduce our insurance costs.

one of the subjects in this month’s issue is workholding. you may wonder how safety procedures factor into workholding. actually, safety is a major aspect of workholding in a gear shop, or in any machining operation, in fact. When designing workholding devices it is the first consideration, of course, that your design securely and properly holds the part. of no less importance, however, is the safety of the operator when loading and unloading parts. you must take into consideration things such as pinch points, sharp corners or edges, ease of handling the part, consideration of handling the part when it has been cut, and access to the tooling. another prime consideration is the ergonomics of the operator when loading and unloading the tooling. i am sure that all of us have seen machine setups where, although the workholding tool-ing being used is sufficient to securely hold the part while it is being machined, it is very difficult at best to load and unload. These are some of the things that often get overlooked in the design of proper workholding devices.

There is an imporTanT safety subject that comes up so rarely that we tend to ignore it, or even to forget about it. This subject is safety signage. a lot of us have made a tour of our shop at some point, often when we first opened the business, and posted the signage that we felt was neces-sary. We then figured we had complied with the intent of the regulations and promptly forgot about them. We realize that the regulations have changed over the years, of course, and we might have even added some signage when we heard about a new requirement, but have you considered the changes that have occurred in your own shop? each time we replace or add a piece of equipment there are new signs that we should be posting. every machine in our facilities should have the appropriate signage pertaining not only to operation, but also to the personal protective gear required when running the equipment. it is also required to have lockout/tagout points identified, as well as any special

requirements pertaining to this particular piece of equipment. often a sign stating that all of the protective guarding furnished with the equipment must be used would be an appropriate addition.

another area that is often missed simply involves changes in the shop layout. are all of the signs that we used to have in place still there, and are they readable? by changing the layout of our shop, have we created a situation where safety signage is not posted where it needs to be? What about things like fire extinguishers; are they well marked so a new employee would have ready access to them? is there enough space around fire doors and electrical cabinets, and are they well marked

“When designing a workholding device it is of the first consideration that it securely and properly holds the part, but of no less importance is the safety of the operator when loading and unloading parts.”

siteSAFETYEquipment must be designed to accomplish the

task at hand, of course, but it’s important that

operator safety be taken into consideration as

well. In addition, signage can play a valuable

role in ensuring workplace safety.

terryMcdoNAldMember of the ANSI Subcommittee on Gear Safety

AbOUT ThE AUThOr: Terry McDonald is partner and manager of repair parts, inc., and a member and past–chairman of the ansi b11.11 subcommittee on safety requirements for construction, care, and use of gear cutting equipment. contact him at (815) 968–4499, rpi@repair–parts–inc.com, or [www.repair–parts–inc.com].

APRIL 2009 19

when the unit is placed into service it will operate without interruption for three or even five years. it is generally accepted that face load factors greater than 1.1 can be used when the manufacturer can demonstrate that their correction factors for the elastic and thermal distortions expected to occur in service have been proven to provide the required contact pattern.

some 10 years ago, after 10,000 to 20,000 hours, a gear unit had a tooth breakage at the extreme end of the pinion tooth. The cause was determined to be misaligned shaft centerlines that concentrated the tooth forces at the breakage point. The misalignment itself was caused by foundation distortion and the inexperience of the erection people—a classic case of failure due to improper tooth contact. The second incident on another unit occurred between 30,000-100,000 hours, when damage was seen in the mid-tooth section of the pinion. The gear wheel and pinion revealed that distorted geometry had concentrated the tooth forces in the midsection. These geometrical changes from residual stresses had happened over a prolonged time period. as a result an extensive inspection of numerous gear units was undertaken for the sake of collecting data. The size, pitchline velocity, hours in operation, previous inspection reports, and the profiles were recorded to create a service-versus-failure profile. approximately 10 percent of all high-velocity drives were found to be in need of corrective action. This required realignment and, in some instances, regrinding of the profile.

Different designs of gear units were involved. The corrective action deemed necessary was a reeducation of both service and installation personnel, a tooth contact check after 2,000 hours of operation, and a change in manufacturing procedures. These include but are not limited to reduction of residual stresses by subsequent machining, low-distortion hardening methods, and new nitrided steels that provide increased hardness penetration depth. Me quality steels vacuum degassed with 5 grain or finer. forging ratio ≥3.5 and further additional testing of mechanical properties. gears are now operating at speeds and powers that until recently were considered impossible. Material is literally being stretched by centrifugal loads and, although the drives can still perform within the required criteria, more-frequent inspection of the contact pattern would seem a necessary requirement for these state of the art drives.

high-speed sTandards usually require verification of the mating accuracy, and that this record be maintained. This entails recording profile, lead, and pitch deviations. The mating gears are considered as a matched set that must be checked for contact on a checking stand and then when installed in the housing. a thin coating of a material such as the popularly used prussian blue is applied at three locations 120º apart. four or more teeth are covered on a dry degreased gear. The gears must be properly aligned with parallel shafts and at a set distance within the closest of tolerances. The gears are rotated with a nominal torque in their operating direction. up mesh is preferred, pinion pulled upwards/gear downwards. The weight of any pulled-upwards rotor is countered by the tangential load. The acceptable contact pattern has been previously determined and made available to the purchaser’s representative. This is especially necessary as the manufacturer may have made lead modifications for torsion, bending, and temperature. Without modification—which is unusual with high-speed gearing—the contact area would be expected to cover 80 percent of the tooth face. all the records are expected to be maintained for 20 years.

The contact pattern is lifted from the teeth with an adhesive paper that is attached to a notated sheet that has been witnessed and signed. after the running tests at 110 percent maximum continuous speed at partial or even full power, the top half of the housing is removed and the gears are again inspected for any damage and further verification of the contact pattern. The gear’s performance is dependent on the designed contact pattern being maintained throughout its life. The complete drive and auxiliaries are designed for a minimum life of 20 years. it is also expected that

“The gear’s performance is dependent on the designed contact pattern being maintained through-out its life, and complete drive and auxiliaries are designed for a minimum life of 20 years.”

tOOtHTIPS

Gear-drive inspection reveals the effects of residual stresses on face contact in high-speed

gear units. This installment explores the issue and provides solutions.

williamCroSHErAuthor, engineer, and former director of the

National Conference on Power Transmission

William p. crosher is former director of the national conference on power Transmission, as well as former chairman of the agMa’s Marketing council and enclosed Drive committee. he was resident engineer-north america for Thyssen gear Works, and later at flender graffenstaden. he is author of the book Design and Application of the Worm Gear.

AbOUT ThE AUThOr:


COMPANYPROFILE

by russ Willcutt

COMPANYPROFILE

When Willy goellner immigrated to the united states from ger-many in the late 1950s he brought with him business contacts that would lead to the founding of his own company, advanced Machine & engineering (aMe). “The company began by provid-ing contract machining services,” according to the founder’s son, alvin goellner, who is product manager of the company’s fixturing group, “and then grew as it took on new lines as a result of dad’s european contacts.”

Those lines have come to include hennig machine protection devices and spieth precision locknuts, clamping sleeves, guide bushings, hydraulic sleeves, and expansion gibs, in addition to Tschudin & heid linear rollers. aMe also began designing its own equipment, such as aMsaW carbide saws, and components in-cluding aMbush squeeze bushings and aMDisK clamp disks. Throughout this evolution the company has remained 100-per-cent family owned, goellner says. “My father acquired hennig just after he founded aMe, and he was the president of both compa-nies as well. My brother, Dietmar, now holds those positions, and my other brother, harold, is vice president of both companies.”

While hennig’s core manufacturing competency is sheet-metal

fabrication, with its primary market being machine tool machine protection products, gear producers also utilize this line to safe-guard their expensive equipment. aMe’s products are of particu-lar benefit to gear manufacturers, however, such as its carbide saws—useful in quickly and efficiently cutting bar stock—and especially its fixturing/workholding devices. The purchase of a fixturing company some 15 years ago propelled aMe to expand its work in designing and manufacturing stock and custom workhold-ing equipment. This includes dedicated hydraulic or pneumatic fix-tures, aMforce power-off mechanical clamp-force cylinders, aM-roK tombstones, aMfleX/s.a.f.e. self-aligning fixture elements, and the s.a.f.e.-locK line of fixture plates. it also represents the Triag line of modular workholding systems. not only does this type of product/service diversification help aMe remain produc-tive should one market sector sag, it also helps the company’s representatives address a wide variety of challenges when visit-ing with its customers.

“if we’re touring a client’s facility to discuss hennig products, the conversation often leads to other challenges we can help them overcome,” according to Doug robinson, marketing director

AdvAnced MAchine & EngInEERIng CO.

SEPTEMBER 2008 21

FOr MOrE iNFOrMATiON: call (800) 225-4263, send e-mail to [email protected], or go to [www.ame.com].

for both aMe and hennig, “and that’s especially true with workhold-ing. That also points to the strong relationships we’ve developed with our customers, where they’ve come to rely on us not only to make suggestions, but to provide solutions.”

What is often encountered, he explains, is that new equipment is purchased with workholding as an afterthought, even though the capital expenditure was meant to increase both capabilities and efficiency. “and that’s the beauty of what alvin’s group does,” rob-inson says. “We help our customers shift workholding from an af-terthought to a high-performance fixturing program that can really take them to the next level.”

a longtime fixturing expert, goellner oversees the company’s workholding-related activities and is often the point person when discussions turn toward that area. “We might begin by talking about a tombstone they need, and i’ll start asking questions about how it will be used and before you know it we’re talking about some dedicated machining on that tombstone, and then the clamps and components they’ll need to hold their parts, and then vices,” he explains. “so we’ll start off talking about a single device and end up discussing a complete turnkey package.”

aMe has experienced engineers on hand, and it backs up its work by providing cMM reports on parts made using the equipment they design. it has also established a strategically located network of representatives to make sure that its customers’ needs are met immediately. “i’ve found that a quick response is one of the most important things a person can provide, no matter what business they’re in,” goellner says. “We’ve placed our representatives very carefully so that they can get to our customers throughout the unit-ed states and canada quickly when they are needed.”

With advanced Machine & engineering’s wide variety of products, equipment, and services—in addition to its reputation for quality, accuracy, and excellent customer service—it expects to continue expanding its capabilities based on its customer’s needs. in sum-ming up the company’s core philosophy, robinson says that “we can provide a value-engineered solution of the highest quality and precision in order to maximize our customer’s production output. We’re here to share our creativity and expertise so that our clients can realize their professional goals, which allows aMe to do the same.”

Whether it’s tombstones, mechanical clamp-force cylinders, or self-aligning fixture elements, this company has the answers to your workholding challenges.

While grinding is the traditional finishing technique for hardened steel gears, hard part turning provides quite a few benefits that may improve your process, and your product.

Hard

Turn

by c

hriste

r rich

t

since its broader introduction in the mid 1980s hard part turning has evolved considerably as a machining process. Developments of machinery, component material, hardening processes, cutting tools, and complete set-ups has made the metal cutting of hard-ened parts an attractive alternative to grinding, and easily acces-sible for any machine shop involved in gear manufacturing.

History of Hard turningThe conventional solution to finishing hardened steel parts has been grinding, but there are a number of clear benefits to the machining of hard parts with a cutting tool. These have justified many exisiting

applications that are growing in number, especially involving turn-ing and milling. hard part turning (hpT) should not be seen

as the alternative to all grinding operations, however, and there are also applications where the two processes

complement each other.hpT was early recognized and pioneered

by the automotive industry as a means of improving the manufacturing of trans-

mission components. gear-wheel bearing surfaces are a typi-

cal example of early applica-tions converted from grind-ing to hpT using inserts in polychrystalline cubic boron nitride (cbn). Today

hardened components are machined widely across many

different industries. case hardened steel components are typical, often having

a hardness-depth of just over 1 mm, giving it a wear resistant case and a tough core. components

that make use of this combination of material properties include gears, axles, arbors, camshafts, cardan joints, driving

pinions, and link components for transportation and energy products, as well as many applications in general mechanical engineering.

defining Hard part turningin its broad definition, hpT is the single-point turning of workpieces with a hardness of above 45 hrc although most frequently the pro-cess concerns hardnesses of 58 to 68 hrc. The workpiece materials involved include various hardened alloy-steels, tool steels, case-hardened steels, superalloys, nitrided irons and hard-chrome coated steels, and heat-treated powder metallurgical parts. it is mainly a finishing or semi-finishing process where high dimensional, form, and surface finish accuracy have to be achieved. The following benefits of hpT have been experienced by users of the process:

• easy to adapt to complex part contours• quick change-overs between component types• several operations performed in one set-up• high metal removal rate• same cnc-lathe as used for soft turning is possible• low machine tool investment• environmentally friendly metal chips• elimination of coolants in most cases• small tool inventory• occupies relatively small machine shop space• advantageous surface finish in many cases.

HardnessWhen steel is hardened it may become twice as hard as it is in the soft condition. hardness adds to the resistance of a material to be plasti-cally deformed and to be penetrated by another material, but the harder the metal, the harder it is to cut. in machining the hardness of the work-piece material generally makes a considerable difference in how well a cutting edge stands up to demands. for application purposes there is hard steel (45-55 hrc) and extra-hard steel (55-68 hrc). generally, the harder the mate-rial the lower the cutting speed, or shorter the tool-life. When component hardness exceeds a certain limit, a change to a harder tool material is needed: a hard cemented carbide insert will perform satisfactorily within a lower hardness range (up to 45 hrc), much harder and they are usually not a practical solution. Most hard components are in the region of 55 to 68 hrc, and this requires a harder, stable tool material such as cbn or ceramic inserts to provide the cycle times and quality consistency needed today. cbn is much harder than cemented carbide and ceramics, while diamond is harder than cbn but useless in ferrous materials. it should also be noted that cbn should be avoided in materials with a hardness lower than 45 hrc due, somewhat surprisingly, to rapid tool wear.

toughnessThis is also an issue in hard part turning, in that mere hardness leads to brittleness. some hard components have long, continuous cuts in stable conditions, which make high demands on hardness for wear resistance but low demands on toughness. some com-ponents, however, have various degrees of intermittance, and some have unstable condi-tions, needing edge toughness. component intermittance may be in the form of gear teeth, slots, surface unevenness, burrs, etc. instability comes from weak machines, set-ups, and components, as well as overhangs. These phenomena generate various magni-tudes and directions of compressive or tensile stresses and strains on the cutting edge. Very hard tool materials such as cbn and ceramics thus need varying combinations of toughness for edge strength. generally speaking, high hardness is needed for the material demands on the tool while toughness is needed for the mechanical loads on the tool.

Expected resultsThe absolute majority of operations in hard part turning are finishing operations, many with

very high dimensional, form, and surface finish tolerances. The first indicator of excessive tool wear is usually the deterioration in maintaining these tolerances, emphasizing the need for selecting the right cutting tool as well as for it to be correctly applied.

in well-optimized hard part turning set-ups a surface finish ra 0.25, rz 1 micron have been achieved and accuracy levels of 0.01 mm on a diameter. other typical values that may be part of demands on hardened components are roundness, conical accuracy, and surface pro-file bearing, all of which hpT responds to well.

a minimum amount of working allowance is vital for both hpT as well as grinding, depend-ing upon form and tension-conditions from the hardening process. The minimum value depends upon component size and cross-sec-tional differences, but if 0.1 mm is suitable for grinding, the hpT-value should generally be an additional 0.1 mm, bringing it to 0.2 mm.

Hpt demands and prioritiesWhen selecting cutting tools for hpT the hard-ness of the workpiece material, machining conditions, and tolerance limits are the main points to consider.

cbn is the most widely used hpT tool mate-rial because it fulfills the requirements made in most applications. Today there are various cbn insert grades available that cover the different operational demands of hpT, including cutting speed, feed, continuous or interrupted cuts, and surface finish demands and conditions. ceramic inserts represent a lower tool cost but are limited to continuous cuts when thermal shocks are small. also, they are not as suitable for super finishing as cbn inserts are.

hpT is more demanding than soft turning because of the higher cutting forces involved, in combination with the tight dimensional and surface finish limits. as an indicator, hard steels typically have a specific cutting force of 3250 n/mm2 at 45 hrc, while extra hard steel has 6450 n/mm2 at 65 hrc. The harder workpiece material needs a strong cutting edge, and this means a relatively blunt edge. The insert cross-section has to be large and strengthening lands and micro-edges need to be added, depending upon the operation at hand. The result of this is often even higher cutting forces and, consequently, the higher demands in hpT for rigidity, stiffness, and stability throughout the set-up, from the cutting edge to the machine tool base.

The general stability, rigidity, and condition of the machine tool are directly decisive as to the level of cutting data, type of cuts, and results that can be achieved. The effects of intermittent cuts and the demands of acheiv-ing super-finish limits should not be underes-timated in hpT. The dynamic stability and the behavior during the cut of the machine often determine the practical limits. Knowledge of the machine behavior during the stress of hpT and the condition of the machine are therefore quite important. Minimizing the amount of over-hang of the workpiece and the tooling is always critical to determining overall rigidity, but even more so in hpT.

The setting up and orientation of cutting tools is also more vital when it comes to hpT. centerline setting of the cutting edge should be very accurate, and the direction of and support against cutting forces in the form of well-supported parts of the toolholder, turret position, and machine should be assessed. insert locking needs to be uncompromising, as does the tool holding, where only the most stable solution should be considered. a basic success factor of hpT is minimizing any move-ment or vibration tendency of the system

Fig. 1: Gear-wheel bearing surfaces are a typical example of hard part turning applications, often converted from grinding. Indexable inserts in polychrystalline cubic boron nitride are used primarily.

Fig. 2: Most hard part turning involves hardnesses of 58 to 68 HRC, which means higher temperatures and cutting forces than soft-material turning. The hard workpiece material needs a very hard, strong cutting edge and stable conditions.


elements such as the insert, toolholder, and tool clamping, as well as the machine turret, spindle, slides, frame, and base. Whereas in the past only a few cnc lathes could be picked on the basis of suitablity for hpT, or could be modified to stand up to the higher demands, many of today’s cnc lathes can perform hpT with good results and cycle times.

tackling the Soft IssuesThe hpT operation will inherit any form and dimensional deviation from previous soft turn-ing. for example, an excessive tolerance for

soft turning on the working allowance for hpT can mean unsatisfactory results, partly because hpT uses such small depths of cut. it is therefore vital that sufficiently-close tol-erances are established for the soft turning based on the experience gained from hpT operations.

The soft turning should reflect the demands made on hpT results especially as it regards form and dimensional accuracy. The soft turn-ing should not be seen as just a roughing opera-tion but as the close semi-finishing operation, as the hpT operation should not be expected to correct deviations or distortions. Thus, the qual-ity of the soft turning operation—as well as that of the hardening process—will directly affect the quality, tool life, and productivity of hpT.

furthermore, variations of the working allow-ance and form passed down from the soft turn-ing also lead to cutting force levels varying in hpT, which means compromising cutting data to cope with the highest force level. This is often in the form of feed rate having to be low-ered to minimize tool or component deflections during the cut. as the feed directly infuences the machining time, this becomes a productiv-ity as well as a quality and security issue. it is always more cost-efficient to tackle the soft-turning issues than the those related to hpT.

Fig. 4: Insert geometry is an issue for hard part turning. The right entering angle, edge nose radius, chamfer, and honing make a significant difference to performance. Wiper inserts can provide an advantageous feed rate and surface finish combination.

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Fig. 3: Crater wear is the dominant type of wear in hard part turning as a result of the high pressure that the chip exerts on the cutting edge. This is countered by selecting the most suitable insert grade for the application in question.

APRIL 2009 2�

Cutting tool developmentsas productivity is an increasingly important factor for hpT today, tool developments play a more-important role. Trends include that of cut-ting speeds having been elevated to present potential levels—well above 200 m/min with some grades—with longer, more-predictable tool lives. feed rates have also been pushed higher to achieve shorter cutting times, though resulting in higher cutting forces. These forces,

however, are countered with various geometri-cal cutting edge designs and larger or different insert nose-radii concepts.

insert grades are becoming ideally positioned to respond to today’s operational demands in hpT. These include continuous cuts of various lengths, light intermittent cuts to heavy inter-mittent cuts, as well as differences in machin-ing conditions. cbn grades are generally the first choice, backed by a ceramic grades, and recent developments have been considerable,

resulting in a new generation of more-capable insert grades.

Tool wear in the form of craters forming on the cutting edge dominates in hpT as a result of the high pressure from large cutting forces combined with high temperatures in the concentrated machining zone. cbn is the tool material best equipped to stand up to the demands involved in hpT with high hardness and varying amounts of toughness. The most recent cbn-grade development has provided the means to limit tool wear further, improve edge security, and extend the application area, as well as to allow cutting speeds to rise by some 20 percent.

Today’s hpT needs a range of tool materi-als that can optimize different conditions, operational demands, and quality results. The following is one such range of different grades that complement each other:

• low-content cbn for continuous cuts which may include occasional, light intermittent cuts with stable machining conditions at high cutting speeds, primarily for case-hardened steels (cb7015);

• Medium-content cbn for operations char-acterized as having substantial amounts of light to heavy interrupted cuts mixed with continuous cuts at medium cutting speeds, often characterized by poor entry-into-cut condtions such as burrs and unchamfered corners on mainly case hardened steels (cb7025);

• extremely hard cbn grades with high edge toughness for severe conditions where the

Fig. 5: To tackle hard part turning suc-cessfully you need a range of tool ma-terials to enable the selection of the best insert for optimization. Continuous cuts, light intermittent cuts, and heavy interruptions and distortions need the right cubic boron nitride insert grade.

2� gearsolutions.com

component shape varies considerably and major distortions may prevail, or where there are unchamfered interruptions primarily on hardened steels (cb7050);

• a mixed aluminium oxide-based ceramic grade with good heat-resis-tant properties and high wear resistance, but limited to light, continu-ous finishing in good, stable machining conditions (cc650).

Alternative Insert geometriesWhen it comes to insert geometry, cutting edges for hpT are relatively dull because bluntness is needed for high edge-strength. This, however, does not mean that geometrical issues are nonexistant. although chip-breakers are not part of the insert face, edge chamfers, honing, nose radius, wiper radii, and entering angle combinations are critical new care-fully-developed features to achieve higher performance and results.

as an example, a correctly designed 30-degree edge chamfer on a cbn edge for hpT helps to direct the crater-making forces further away from the edge, reducing the weakening effects of this type of wear. There are main-ly two types of chamfers: the s-type, where the land is complemented by light honing for added strength, and; the T-type with no honing, giving rise to the lowest cutting forces and best surface-finish generating capability. The wiper insert is based on a sophisticated radii-combination edge con-cept that has revolutionized finishing turning, and has come to improve hpT as well. There are now specially developed wiper inserts for hpT for both finishing and semi-finishing operations. a Wh geometry generates the best surface finish, while providing high feed rate capability with either T- or s-land edges. a Wg geometry is suitable for semi-finishing operations when performed at stable machining conditions, when cut-ting forces are higher but so is the feed rate capability. in comparison,

the standard nose-radius insert generates the lowest cutting forces with low stability requirements, but it does not have the high productivity/sur-face finish combination of wipers.

Fig. 6: The locking of the cubic boron nitride corner on multi-corner inserts for hard part turning needs to be very secure so as not to be a source of instability. Safe-lok me-chanical interlocking provides an absolute bond for a corner that copes with most types of cut.


a subsequent new innovation involves an insert geometry with a straight cutting edge, presented at a carefully balanced, smaller enter-ing angle, blended with a wiper edge. an Xcel geometry insert generates a chip with an even thickness, eliminating extremes as regards wear mechanisms. Thanks to the load from a more-constant chip and the reduction in heat development in the cutting zone, slower and more advantageous tool wear development is achieved for this and many other hpT operations. benefits are especially high when the whole edge is used for one-pass operations.

This insert leads with a very small entering angle (10 degrees) along the main cutting edge, which reduces the chip thickness relative to the feed rate. This then allows much higher feed rates to be used, leading directly to shorter cutting times.

Multi-corner indexable inserts for hpT are typically cemented carbide inserts with cbn corners. in the past this has meant a potential source of instability or weakness at the joining of the two materials in the insert. The locking of the cbn cornerpiece onto the basic carbide insert needs to be very firm, with no inherent instability or weakness. it also needs to accomodate enough capability for the insert to perform the frequently occurring cuts in turning such as profiling, facing, back turning, undercut-ting, and chamfering. Today’s brazed cbn/carbide insert—in addition to taking long, continuous cuts—also needs to cope with relatively severe intermittent cuts and elevated cutting data in order to provide higher productivity in hpT operations.

a new, solid, mechanical interlocking method and brazing design has provided a longer, multicorner cbn edges with high insert stability, removing a multicorner inserts limitation. With the brazed joint being further away from the intense heat of the hpT machining zone, the insert has become more capable of continuous cuts at higher cutting speeds.

safe-lok mechanical interlocking provides an absolute bond, resisting higher pressure from larger feed rates, depths of cut, and the added severity of more-substantial intermittent cuts.

Movement and vibrations of the insert in the seat is a well-rec-ognized culprit that affects the component quality and leads to pre-mature edge breakdown. for this reason clamping the insert in the toolholder is the next vital step in the stability link. a rigid clamping system, type rc, combines the downward force of a clamp on the insert with precise, well supported tip-seat positioning. The result is very rigid insert clamping and high indexing repeatablity to suit a majority of turning applications, and especially to hold and support cbn and ceramic inserts in hpT. indexing of insert and shim is facili-tated by the design of the clamp set.

tool-path Strategiesan hpT application can be optimized using wiper inserts or conventional nose-radius inserts by adopting either a one- or two-cut strategy for machining. The one-cut way of hpT is the quickest but entails acheiving the required finish and accuracy in one cut. Demands are made on tool life for the tool to maintain component limits, and good stability is neces-sary throughout, as all material is taken in the one pass. on the other hand, the machining time is short, and only one tool is needed.

The two-cut way needs two tools—one for semi-finishing, and one for finishing—and the tool dedication means better quality consistency and longer life per tool. More consistently maintaining higher surface finish and closer tolerances (best process stability) are the main advantage to be weighed against longer machining time. The right type of insert needs to be selected to suit each application.

APRIL 2009 29

Machine Shop Experiencecorrectly applied, hard part turning with modern cutting tools and methods can lead to advan-tages over grinding and outdated hpT such as higher productivity through shorter cycle times; higher production flexibility through the use of cnc lathes; and higher operational capability of turning giving good quality surfaces. lower machine costs with lower-cost machinery can also be realized, and there are also environmen-

tal advantages in using a metal cutting process that requires no coolant. some of the neces-sary conditions for success include:

• a good cnc lathe is recommended, having the right capability, where general stability, high tailstock pressure, and suitable slides are factors without necessarily being a hpT-dedicated design.

• good workholding equipment and minimized overhang are necessary as stability is vital

for example solid center instead of live and well-dimensioned spindle bearings.

• ensure that the quality level of hardened workpieces is consistent, in size, form, hard-ness, run-out, etc.

• use the best of the latest cutting tools, carefully selected for the job at hand with correct machining methods, and get qualified support

• establish the optimum cutting data range to give the best combination of productivity, quality, and security

With regard to cutting tool requirements, make sure there is good accessibility for tools for various shapes of components, very stable insert clamping, strong and stable tool mount-ing, and predictable and sufficiently long tool-life in order to eliminate tool changes during the course of the operation. also make sure there is sufficient tool accuracy and stability, especially concerning the insert, to enable toler-ances to be kept consistently and to minimize adjustments required during the process, and that you have qualified application back-up.

AbOUT ThE AUThOr:

christer richt is with sandvik coromant and can be reached at [email protected]. also go online to [www.sandvik.com].

Fig. 7: Hard part turning has come a long way and today is an efficient man-ufacturing method. Certain conditions need to be in place for applications to be successful, but these can be accom-modated relatively easily, especially with knowledgeable support.


In the third—and final—installment in a multi-part series on

workholding, Toolink Engineering and König-mtm discuss

inspection, special fixtures, and more.by Juergen Kempf and Tim peterson cMfgT

To conclude our three-part series on the principles of workholding we will begin with an overview of inspection devices, both hydraulic and mechanical. next we will intro-duce some holding fixtures for special appli-cations such as tapered bore components, clamping devices with multiple clamping functions, and devices with unique fea-tures for special applications. finally, we will outline some of the application-spe-cific additions that can be incorporated into your clamping systems, including electronic clamping pressure control.

Inspection devicesWhile many companies may have dedicated, quality, precise workholding for the manufac-ture of gears, surprisingly few have equal-quality tooling to inspect their finished prod-uct, let alone a solution that clamps or holds the workpiece in the same fashion as occurs during manufacture.

if your shop is manufacturing high-preci-sion parts it’s a good rule of thumb that your inspection tooling should provide an accuracy error of no more than 10 percent of the part tolerance. To maintain this quality it is dif-ficult and time consuming, if even possible, to operate with a solid mandrel or a simple/rudimentary collet type mandrel. hydraulic or mechanical clamping solutions for inspec-tion can easily replicate, and most frequently exceed, the quality of existing manufacturing tooling.

an obstacle that is frequently faced with inspection devices is weight. Despite the size of the component, heavy steel clamping fixtures are difficult to handle. The repetitive process of loading parts onto the clamping fixture, and then onto centers or the like, can be back-breaking, or simply time consuming if a crane must be used. To combat this König

offers a line of light-metal, or aluminum bod-ied, hydraulic arbors. These arbors offer the same accuracy as their traditional steel coun-terparts, though, and weigh up to 60 percent less. The clamping area remains unchanged, being made of high-alloy tool steel, while the base arbor is made of lightweight aluminum. high-speed steel inserts are used for the cen-ters and other wear areas, such as the axial location surface. all other functional aspects are identical to steel versions. This tooling design is ideal for measuring, balancing, turning, gear grinding, and other applications, assuming that minimal heat is imparted to the clamping device during the process.

When weight is not an issue, nearly or exactly the same device that is used to clamp your components during manufacturing can be used for inspection. arbors and chucks can be actuated manually, or by whatever method is available on the machine for auto-mated inspection.

given the increasingly common use of analytical gear inspection machines, another hurdle for inspection applications is providing clearance for the measuring probe to allow the machines to measure lead, involute, and runout, for example (fig. 1). in this situation both a colleted hydraulic arbor and a mechani-cal arbor are available. given the hydraulic solution, the base arbor is sized well below the diameter of the clamping area. The base arbor is then fitted with a “pocketed” collet (fig. 2) that allows at least four pockets for probe clearance in between the other contact areas of the collet on the clamping diameter. These arbors can be prepared for use with multiple diameter collets and changeable axial support flanges. if your workpieces have smaller differences in bore sizes, but enough difference to exceed the clamping range of a direct-clamping hydraulic device, a mechani-cal “four leg” arbor may be ideal.

The four leg arbor is a mechanical device through which the workpiece is centered and clamped over four “legs” that are operated by hand over an integrated torque limiting device. This design of arbor offers up to 600 microns of expansion while still maintaining runout accuracies of 5-10 microns.

Special toolingyou have all encountered a tricky compo-nent or an application that challenges your machine’s capability, or a part that is simply a bear to hold during machining. There are always those who will give you fits determin-ing how to clamp the part while locating on the datums, etc. König prides itself on offer-ing solutions for your challenges. perhaps you have a tapered bore. occasionally a bore is lined with a soft metal bushing such as copper or brass or aluminum that could be damaged. if you have ever thought, “if i could only…” chances are that König has.

for tapered bores, hydraulic expansion arbors are a solution, and face clamping is not always necessary. if the taper of the bore is less than 5° it can be clamped directly on a tapered hydraulic arbor. for greater flex-ibility you can also use straight hydraulic arbors with a slotted collet and a tapered oD geometry. a straight arbor using tapered col-lets can accommodate the same total taper angle of 5°. on taper angles higher than 5° König offers mechanical, solid mandrels with automatic actuated ejectors, for use on gear grinding machines, for example.

To clamp on a soft metal sleeve, König offers a hydraulic expansion arbor with a plastic expansion sleeve. This softer plas-tic sleeve contacts the workpiece without scratching or marring, and the sleeve or collet can easily be replaced as it begins to wear.

in some instances arbors and chucks can be combined in one device to offer both iD and oD clamping. for example, on a reishauer rZf machine the same device has iD clamping for the bores of the dressers, while at the end of the device is a chuck for oD clamping on the journal of the component (figs. 3, 4). hydraulic devices are not always limited to one clamping area or diameter and are in fact fully capable of having multiple clamping areas, as well as multiple clamping diameters.

at other times, when significant torque is being transferred to your component, addi-tional clamping force beyond radial clamping may be necessary. in this scenario additional clamping force can be gained by combining hydraulic face clamping with radial clamp-ing force. This design of arbor utilizes three hydraulic ports—in this case, of a Kapp KX 300—to clamp radially, then swing out the

Fig. 1: Measuring probe


“swivel hooks” and clamp axially (face clamp-ing), and finally to retract the swivel hooks and unclamp the device.

To locate and align gear shafts between centers while clamping on an outside diam-eter that is not running with the center, König has designed a mechanical chuck with radial adjustment. The chuck has an integrated center to align and locate the shaft between chuck center and tailstock center. The chuck operates with changeable slotted collets that

enable you to use this type of chuck for more than one clamping diameter. This arrangement has proven to be very successful, for example, on several hoefler machine applications.

The collet is actuated over a clamping bell, and this clamping bell is located over a wobble device with the base chuck. Through this feature the clamping collet follows the out-side geometry of the component and doesn’t align over the collet. With this configuration you have an effective drive dog system for

Fig. 2: “Pocketed” collet

Figs. 3 & 4: ID (top) and OD clamping

APRIL 2009 3�

locating between centers while enabling you to clamp and load/unload automatically.

for turning powder metal gears on horizontal lathe machines with automatic loading, König-mtm developed a hydraulic expansion arbor with a retractable axial stop flange. The retract-able support flange, or axial stop, allows you to turn the gear on the top and bottom face in one operation.

The arbor is actuated over a drawbar. The first 10 mm of the clamping stroke clamps the part on the arbor, and the remaining 35 mm of the clamping stroke retracts the axial stop flange to provide enough space to turn the rear side of the gear within the same operation. The procedure of securely clamping the part first before retracting the axial stop is man-aged through an integrated actuation system inside the arbor. powder-metal companies have used this arbor design with great success for increased quality and a reduced production time.

Electronic Clamping pressure ControlWith hydraulic clamping devices, and manually actuated arbors and chucks in particular, it is easily possible to reach a clamping pressure

that is too high or too low, each with their own disadvantages. Typical expansion rates of hydraulic mandrels and chucks fall into the range of a maximum of 0.3 percent of the clamping diameter. While this provides suffi-cient clamping in some circumstances, others require a more accurate clamping pressure.

if clamping pressure is too low the compo-nent can shift axially, radially, or both on the mandrel. said effects could include not only

unacceptable component quality, but could completely ruin the tool during the machining process. The costs associated with a machine crash add up quickly when you consider the tool replacement, workholding repairs, scrap, and resultant downtime. at the other extreme, if the clamping pressure is too high, sensitive, or thin-walled, workpieces can be deformed. once machining is completed the stretched workpieces return to their static form and

Fig. 6: Layout and display of the König-dorn clamping pressure control dms 1

Fig. 5: Pressure sensor’s magnetic contact


specified tolerances cannot be kept.To remove any doubt an electronic clamping

pressure control can be included in your clamp-ing solution. During manufacture the arbor or chuck is outfitted with a pressure sensor. The pressure sensor is then connected to a digital readout (Dro) via dirt-insensitive, mag-netic contacts (fig. 5). for manually actuated devices the clamping pressure can be read digitally on the Dro as the actuation screw is turned, enabling maximum control and repeat-able clamping pressures for each use.

for automatic clamping or actuation initi-ated over the machine, an upper and lower limit is determined and preset in the control. The device can be connected to the machine through a pressure-free outlet, thus allowing any disturbances or changes to be moni-tored and/or recognized immediately by the machine’s control system with the measured pressure displayed from 0-1,000 bar (fig. 6).

use of electronic clamping pressure con-trol not only guarantees the same clamping pressure in a König arbor or chuck, but it also eliminates potential variation from one operator to another, ensuring consistent and repeatable results while sparing damage to expensive tools, components, and manufactur-ing devices.

Application-Specific AdditionsTo further customize your workholding, and to help continue capitalizing on your tooling invest-ment, several additions can be made to your workholding solution, depending on the applica-tion. Most of König’s hydraulic devices include an adjusting screw. given the nature of the function of a hydraulic expansion device, there are internal seals that can wear in time. as the seals wear or begin to harden, small amounts of hydraulic oil can be lost, resulting in a loss of clamping pressure. To resolve this, an adjust-ing screw is included. after several clamping cycles, if there is a slight loss in clamping pres-sure, you can simply turn the adjusting screw as necessary. The adjusting screw moves a piston, which then forces a “reserve” of hydrau-lic oil back to the front side of the actuation piston/system, thus maintaining the necessary volume of oil for expansion of the clamping sleeve and, finally, your component.

for automatically actuated devices, the previ-ously mentioned manual adjustment can be avoided by using an automatic adjustment device. The function is the same, although the adjustment is made automatically, as needed. The auto adjustment device consists of a

Fig. 7: Königdorn clamped (left), unclamped (center), and being readjusted, right

APRIL 2009 37

spring-loaded piston that is constantly under pressure. if any amount of hydraulic oil is lost the spring forces the piston in, displacing the lost volume of oil and maintaining clamping pressure. The piston cannot be forced back under pressure thanks to a ratcheting-tooth type design.

along the same lines as the adjusting screw, an operation indicator pin can also be added to arbors and chucks, assuming they are clamped over an external oil supply (fig. 7). The operation indicator pin protrudes through a cut-away nut. The pin is fully extended when the device is clamped, while the pin is retracted slightly when relaxed. as an added feature, the pin has colored bands. if the bands are no longer visible, this is an indication that the Königdorn is in need of adjustment.

in some applications where volumes are high or additional torque is needed, coatings can be used on the clamping surface. König uses an Mhb coating that increases the surface coefficient from 0.1 to 0.15, providing up to 50 percent more clamping force. These optional coatings increase wear resistance, while also providing the added benefits of higher torque transmission and/or corrosion resistance (fig. 8).

on occasion it is also necessary or beneficial to add a spiraled groove to the clamping surface (fig. 9). Through experience König has found that during part changes—and the machining process in general—a thin film of oil can form on the clamping surface. Without the spiral groove, when the device is actuated or clamped the film of oil trapped between the

Fig. 8: Coated for corrosion resistance Fig. 9: Shows spiral groove and MHB coating


iD of the component and the oD of the clamping surface (or vice versa) could act as a fluid bearing or cushion of sorts. not only could this reduce the torque or clamping force, it could also be a safety hazard, as the part could potentially be flung from the clamping device during machining. This spiraled groove provides a channel for any oil trapped between the part and clamping surface to be routed out and away from the action.

finally, when an application calls for a workpiece to locate on a flat face that may not be qualified or running with the bore, a pendular device

or wobble plate can be implemented. These wobble plates vary in com-plexity as necessary, yet can be as simple as an o-ring that will allow some “give” as needed.

in summary, through our three articles (all available for download at www.gearsolutions.com) we have introduced and briefly discussed some of the principles of workholding and the different designs and/or configu-rations that are available. We have also touched on a few applications yet clearly not all. our intent was to encourage a review of your current workholding, and identify weaknesses that could benefit from a more robust, easier to use, higher precision workholding solution.

Workholding is often overlooked as a means through which to cut costs and improve upon quality, but the truth is just the opposite. improved clamping solutions can reduce setup and changeover times while also reducing individual part cycle times, producing higher qual-ity, more precise parts in the process. The end result is less scrap, increased productivity and, ultimately, increased profits.

König-mtm has identified their individual strengths in the workholding arena and has longstanding relationships and product knowledge of sev-eral major machine tool builders. They are proven candidates for high pre-cision and challenging workholding solutions both in manufacturing and inspection. We encourage you to “get a grip” on your workpieces and reap the benefits that improved workpiece clamping solutions offer.

AbOUT ThE AUThOrS:Tim peterson, cMfgT, is the engineering and sales manager for Toolink engineering, the exclusive north american distributor of the König line of workholding. Juergen Kempf is a mechanical engineer and technical sales manager for König-mtm in Wertheim, germany, and the primary technical contact for north-american customers. peterson can be reached at (303) 776-6212 or [email protected]. Visit online at [www.toolink-eng.com] or [www.koenig-mtm.de].

Fig. 10: Plastic sleeved arbor

APRIL 2009 39

Smart manufacturers can maximize their workholding investment by learning how to use these devices efficiently and to the full extent of their capacity. Drewco provides important tips.by ann pettibone

Workholding that works

to machine new parts, or new parts can be added to existing fixtures. additionally, the life of collets, chucks, and components can be sig-nificantly improved by changing materials, heat treating, web design, and over-travel protection.

Increasing Capacityone way of increasing capacity is by changing the part-holding meth-od; for example, changing from multiple large dedicated part supports to movable supports has proven to reduce setup time by 88 percent. This kind of change in part-holding method also increases quality by reducing operator error and adds floor space by reducing storage requirements.

another would be to expand the family of parts being held. Workholding should always be designed initially to provide for future part additions or variations. conservatively, more than 50 percent of all hobbing and grinding workholding fixtures have the inherent capac-

ity to handle additional part sizes. expanding the family of parts that your workholding fixtures hold is, of course, one of the most effective ways to inexpensively improve production capacity (see fig. 1).

To look at expanding the range of parts that can be run on exist-ing fixtures, two areas will need to be considered: machine capac-ity, and current fixture flexibility. The parts to be added to the fixture will be examined for pitch diameter, helical angle, bore size, and face widths. Many times a few minor changes to the existing fixture can improve the fixture and allow faster changeover of existing and new parts. as an example, we were recently asked to add 22 more gears to a fixture we’d originally designed for 120 parts. With the addition of seven more collets the customer gained 20 percent more machine capacity.

you can also have your quick-change fixtures multitask by making them interchangeable between machines, adding or redesigning uni-versal bases into the fixtures. Most gear manufacturers have demand for short runs, and in this economy that demand has increased. retrofitting fixtures with universal bases and quick-change features inexpensively adds agility (see fig. 2).

in addition, you can color-code exchangeable workholding compo-nents to increase setup speed and reduce operator error. operators are under even more time constraints now. The no-cost color-coding of collets to match parts or part families reduces costly errors and saves both parts and tooling (see fig. 3). What in a different economy may have seemed like tweaking can now make a much-needed dif-ference. small enhancements to tooling improve operator speed and ergonomic comfort; e.g. access to activation screws, anti-rotation pins, machine orientation, and other limiting factors.

like most manufacturers, gear manufactur-ers today find themselves with the challenge of maintaining viability, maximizing profits, and enhancing productivity. Most are also experiencing varying states of budgetary con-straints. Whether you have no budget, or some form of a limited budget, the takeaway from the current economic situation is clear. it is the old adage “make the most of what you have.” low- or no-cost solutions and innova-tions play a vital role in improving agility and sustaining a competitive strategy. We now continually hear the lament from engineers and production managers that are asked to improve production without significant spend-ing, and to do it quickly. in many situations an answer can be found in low-cost workholding solutions. improving workholding can now gen-erate significant cost savings. you often don’t have to make major capital expenditures, buy new machines, or redesign whole processes to increase production and reduce costs.

in a booming economy the vital role of work-holding is often lost in the activity of new cell development, or inside the process of major capital expenditure of new machines. When these activities produce satisfactory results, the refinement and added significance of well-designed workholding can often be lost or become an afterthought. We have even had several customers who, in the complicated process of selecting and purchasing new machine, have forgotten to order workholding. but right now workholding can become the resource that makes the difference that gear manufacturers need. Workholding can address productivity and profitability, representing low-cost actions can make real improvements.

all workholding suppliers would like to be designing and manufacturing shiny new work-holding components. currently, however, help-ing gear manufacturing customers make the most of what they have may in many cases be just what the doctor ordered, and how the workholding industry can be of the best ser-vice to its gear customers.

Where can workholding help? When design enhancements, refurbishing, protection, and planning are implemented, workholding can go a long way toward create big returns with the least cost and lead times. design EnhancementsWithout major manufacturing budgets, oppor-tunities to refine and maximize the current processes still abound. Design enhance-ments include changes that either improve setup and/or run time, or provide changes that adjust for any current issues or deficien-cies. Design enhancements encompass sev-eral options. existing fixtures can be recycled

Fig. 1: Quick-change expandable fixture

providing process ImprovementsDesign enhancements can facilitate the profitable moves to improved processes. The important switch to the dry hob pro-cess can be facilitated with new rigid workholding and tooling (fig. 4). We have seen our customers get 62-percent more parts production between tool sharpening

and at least a 25-percent improvement in cycle time. They also enjoyed the benefits of a cleaner environment.

adding clamping as close to the pitch line as possible allows for increased gear teeth cutting speeds through improved workholding rigidity. reducing the amount of clearance required between the grip diameter and the relaxed state of the col-let can reduce costs through extending

the life of collets. The total distance that a collet travels can be broken into three zones: load clearance, grip tolerance, and amount of over-travel.

historically, with manually loaded work-holding, the amount of load clearance was kept at a minimum. With automated load-ing systems, however, the amount of load clearance required has increased. This moves the gripping diameter toward the

Fig. 2: Universal base fixture, interchangeable between multiple machines

Fig. 4: Dry hob rigid tooling

Fig. 3: Color-coded collets


other end of the travel, where the internal stresses reach a maximum. adding a lead to the end of the collet helps to guide the workpiece over the collet. This, combined with a more-stringent setup of the auto-mation, can help make this a reality. We have seen customers reduce the amount of load clearance and gain collet life that is doubled, tripled, and more by creating these minor changes (fig. 5).

processing gears by machining the finished bore first is more cost effective than trying to finish the bore while locat-ing off of the pitch line. changing to a col-let fixture, which is more forgiving to tight tolerances, generates cost reductions.

finally, when it comes to design enhancements, communication is king. communication is vital to getting it right the first time, and it is also imperative

when it comes to improving on a current process. at Drewco we favor a quote from business author Ken blanchard: “none of us is as smart as all of us.” Workholding experts have seen hundreds of design issues, and they have developed as many solutions through design or manufactur-ing methods—many at very little cost. be sure to ask for a consultation and share your thoughts, issues, and goals fully.

Fig. 5: Load clearance graph Fig. 6: Refurbishing a chuck body used in ID grinding

APRIL 2009 43

issues that may not seem fixable, or ones that you just live with, can actually have a very workable solution.

refurbishingWhether it is a smaller interchangeable component, whole chucks, or a machining center fixture, refurbishing is a relatively inexpensive way to improve tooling function while also improving tooling life and its function (see figs. 6, 7). in addition, manu-facturing firms are often unaware that they can extend the life

of workholding that, in a more progressive economy, would be considered perishable. so don’t throw it out, refurbish it!

Manufacturers using worn fixturing often reduce their speed to avoid runout and preserve quality, driving production costs up. refurbishing tooling, from collets to whole fixtures, can double the tool life.

Collets: sometimes referred to as bushings or sleeves, collets that are sealed or bonded can, over time or with certain cool-ants, become brittle and lose their elasticity. This can directly

Fig. 8: Adding a textured surface to improve grippingFig. 7: Refurbishing nose activation angle used in OD grinding

Continued on pg. 50 >


APRIL 2009 4�

GEAR ACCESSORIES, PARTS & TOOLING

FELLOWS Model #10-4/10-2, All Parts Available REF#102Tilt Tables for 10-2/10-4, Qty 2 REF#102FELLOWS Parts Available For All Models REF#103BARBER-COLMAN – PARTS AVAILABLE FOR ALL MODELS REF#103

GEAR HOBBERS/CUTTERS CNC

PFAUTER #PE-150, 6” Dia, 6-Axis CNC, New ‘86 REF#101 LIEBHERR #LC-152, 6”/8” Dia, 7-Axis CNC w/Automation, New ’90 REF#101PFAUTER #PA-320, 14” Dia, 6-Axis, Rebuilt/Retrofit ’06 REF#101G&E #96H, 100” Dia, .75 DP, CNC Universal REF#101G&E #120H, CNC, Gasher/Hobber, Twin Stanchion, 1/2 DP, 42” Face, ‘94 REF#103HAMAI 60H, CNC 4-Axis, 3.5" OD, 9" Face, 12 DP, New ‘89 REF#103LIEBHERR #LC-255 CNC, 6-Axis, 10” Dia, 10” Face, 4 DP, ‘87 REF#103PFAUTER #PE-150, 6-Axis CNC, 6” Dia, 5 DP, 6” Face, Fanuc 18MI REF#103SYKES #H160, 4-Axis CNC Hobber, 6” Dia, All the Features, ‘93 REF#103G&E #60 S-2 CNC Gasher/Hobber REF#103BARBER-COLMAN #16-36, 16” Dia, 4-Axis, 6 DP, 36” Face REF#103G&E #96H, CNC, Gasher/Hobber, New ‘07 REF#103G&E #160H, CNC, Gasher/Hobber, New ‘07 REF#103LIEBHERR #LC-502 6-Axis CNC Gear Hobber, 20" Diam. Cap., Loading REF#103WANDERER GF 345 CNC Hobbing and Milling Machine 4-Axis 24" Swing REF#103LIEBHERR #ET-1802 CNC – 98” Diam REF#103MUIR CNC Gear Hobber, 4-Axis, 118” Dia REF#103PFAUTER #PE-800, 3-Axis, 31.5” Dia REF#103 LIEBHERR #ET-1202 CNC - 70” Dia REF#103G&E 120/188, CNC Gasher/Hobber, 188” Dia REF#103GLEASON #125GH, 6-Axis Fanuc REF#103TOS OFA Series CNC Gear Hobbers, 12” & 40” Dia REF#105TOS OHA Series CNC Gear Shapers, 12” & 40” Dia REF#105TOS OFA 32 CNC 6 13” Dia 11” Face REF#105

GEAR HOBBERS/CUTTERS

KOEPFER #150, 6” Dia, REFurbished w/Accessories REF#101KOPEFER #151, 6” Dia, REFurbished w/Accessories REF#101KOPEFER # 170, 5.1” Dia, REFurbished, w/Accessories REF#101PFAUTER #RS00S, 8”/10” Dia, 6 DP, Diff REF#101LIEBHERR #L-301, 12” Dia, 2-Cut, Crowning REF#101CLEVELAND #CR-300, 12” Dia, Crowning, 2-Cut, New REF#101PFAUTER # P-400, 16” Dia, Vertical Universal, High Tailstock REF#101PFAUTER #P-403, 18” Dia, Auto-2-Cut, New ’79 REF#101

LIEBHERR #L-901, 36” Dia, Crowning, Auto-2-Cut, Diff, Yr ’74 REF#101G&E #96H, 100” Dia, 1 DP, Crowning, New ’72 REF#101BARBER COLMAN #3, 6” Dia REF#101BARBER COLMAN #16-16, 16” Dia REF#101BARBER COLMAN #14-15, 14” Dia, Series A-2, Shift, 2-Start REF#101BARBER COLMAN #14-15, 14” Dia, 4-Start Index, Chucking REF#101BARBER COLMAN #16-36, 16” Dia, w/Differential REF#101BARBER COLMAN “Multi-Cycle” #16-36, 16” Dia, w/shift C-Frame REF#101TOS OF-16, 60” Dia, Auxiliary Work-table, Change Gears REF#101BARBER-COLMAN #14-15, 14” Dia, 15” Face, 1 to 4 Start Worm, Several REF#103BARBER-COLMAN #16-16, Multi-Cycle, Dual Thread Worm, Downfeed REF#103BARBER-COLMAN #16-36, 24” Dia, C-Frame Style, 4 1/8” Bore REF#103BARBER-COLMAN #16-56, 16” Dia, 56” Face, Differential REF#103BARBER-COLMAN #22-15, 22” Dia, 14” Face, Differential REF#103BARBER-COLMAN #6-16, 6 Start Worm, Downfeed, Hyd. Clamping REF#103G&E #24H Universal Head, Infeed, Tailstock, Differential, ‘50’s REF#103G&E #36H and #36HWD, Differential, Excellent Condition REF#103G&E #48H REF#103G&E #48HWD REF#103G&E #40TWG REF#103HAMAI #120, 4.8” Dia, 4” Face, 12 DP, ‘70 REF#103LIEBHERR #L-402, 16” Cap, 2-Cut Cycle, Crowning, ‘77 REF#103LIEBHERR #L-650, 26" Dia Cap, 14.5" Face, 2.5 DP, New ‘70’s REF#103MODUL #ZFZW 800, 29.8” Dia, 16.25” Face, 2.5 DP Crowing, 2-Cut REF#103BARBER-COLMAN #1600-36, 16" Dia., 39.5" Face, 6 DP REF#103CHONG QIN #Y3180H, 31.5 Dia., 15" Face, 3 DP REF#103FELLOWS FH-200 Max Diam 7.87" Max Dia Pitch 5.08" REF#103G&E #16H Gear Hobber, 16"Dia REF#103BARBER-COLMAN #3 (6-10), Single & Triple Tread Worm HS REF#103BARBER-COLMAN #6-10, 6” Dia, 10” Face, 16 DP REF#103HOLROYD – 2AC 10” Dia REF#103KOEPFER #140 , 2.75” DIa, 4” Face REF#103 KOEPFER #153B, 5.6” Dia, 5.9” Face REF#103LANSING #GH-32, 32” Dia, 12” Face, 2.5 DP REF#103LANSING #GH-50, 50” Dia, 17.75” Face, 2 DP REF#103LIEBHERR #L-252, 9.8” Dia, 7.9” Face, 4.2 DP REF#103LIEBHERR #L-400, 16” Dia, 11” Face, 6 DP REF#103MIKRON #79 1.5 Dia, 26 DP REF#103PFAUTER #P-630 REF#103STAEHELY SHS-605 REF#103G&E #60S REF#103PFAUTER #RS-00 REF#103G&E #96H REF#103MIKRON #132.0 , 4’ Dia, 12DP REF#103BARBER-COLMAN TYPE T REF#103IUG –Craiova FD-3600 REF#103LIEBHERR #L-401, 15.7” Dia 11” Face, 3DP REF#103LIEBHERR #L-902 36” Dia REF#103MODUL ZFWZ 400-3, 16” Dia REF#103PFAUTER #P-251 & P-253 10” Dia, 9” Face, 4 DP REF#103MODUL ZFWZ 400-4, 16” Dia REF#103OVERTON #HD-400, 15.7” Dia, 12” Face, 3 DP, New ‘88 REF#103FAUTER #P-630R, 25" Max. Spur Dia, 12" Max Rotor Dia. 12" REF#103BARBER-COLMAN #6-20, 6” Dia, 10.5’ Face REF#103SHIBURA HHK-250A Single Index REF#103SCHIESS 1 RF-10, Dia 60” REF#103CRAVEN Horizontal REF#103MODUL ZFWZ-5000, 196” Dia, Special Worm Hobber 86 REF#103TOS FO-16, Max Cut w/support 90” REF#103BARBER-COLMAN 2 1/2 -4, S/N 119, ’62 Hi-Production Spur Gear REF#104BARBER-COLMAN 6-10 SYKES, Triple Thrd w/Lever Operated Collet Assy REF#104BARBER-COLMAN 6-10 B&C Ltd, S/N 8079, Triple Thrd REF#104BARBER-COLMAN 6-10, S/N 4626, ’57 Triple Thrd 3” Hob Slide REF#104BARBER-COLMAN 6-10, S/N 4659R, ’56 Triple Thrd Adj Ctr Assy REF#104BARBER-COLMAN 6-10, S/N 4665, ’57 Fine Pitch Prec Triple Thrd REF#104BARBER-COLMAN 6-10, S/N 4701, ’58 Triple Thrd w/Power Down Feed REF#104BARBER-COLMAN 6-10 M/C, S/N 4755, ’59 Triple Thrd w/MC Conversion REF#104BARBER-COLMAN 6-10 Multicycle, S/N 4778R87, ’60 (’87 Rebuild), Sgl Thrd Hi-Spd REF#104BARBER-COLMAN 6-10 M/C, S/N 4913, ’63 Triple Thrd w/90 Deg Hob Slide REF#104BARBER-COLMAN 6-10 Multicycle, S/N 5055, ’66 Triple Thrd, 800 RPM REF#104BARBER-COLMAN 6-10, S/N 5141, ’67 Triple Thrd w/Prec Hob Shift REF#104

BARBER-COLMAN 6-10 Multicycle, S/N 5148, ’68 Triple Thrd, 800 RPM REF#104BARBER-COLMAN 6-10 Multicycle, S/N 5259, ’75 Triple Thrd w/Auto Hob Shift REF#104BARBER-COLMAN 6-10, S/N 5353, ’77 Triple Thrd w/3” Hob Slide, 800 RPM REF#104BARBER-COLMAN 6-10, S/N 5394, ’81 Fine Pitch Triple Thrd w/Dwell & Hob Rev REF#104BARBER-COLMAN 6-16 M/C, S/N 5238, ’70 Triple Thrd, Recon ‘02 REF#104BARBER-COLMAN 6-10, S/N 5407, ’82 Auto w/PLC Control REF#104BARBER-COLMAN DHM, S/N 105, ’42 Double Thrd REF#104BARBER-COLMAN 14-15, S/N 635R, ’53 Dbl Thrd, Fact Reb REF#104BARBER-COLMAN 14-15, S/N 745, ’55 Dbl Thrd w/Dwell REF#104BARBER-COLMAN 14-15 Dual Fd, S/N 938, ’62 Dbl Thrd, Comp Reco REF#104BARBER-COLMAN 14-15, S/N 1055, ’65 Dbl Thrd w/New Hyd Sys REF#104BARBER-COLMAN 14-15, S/N 1131, ’66 Dbl Thrd w/Hyd Tailctr REF#104BARBER-COLMAN 14-15 Dual Fd, S/N 1261, ’67 Dbl Thrd w/Hyd Live Ctr REF#104BARBER-COLMAN 14-15 Dbl Cut, S/N 1278, ’68 Dbl Thrd w/4-1/8” Bore REF#104BARBER-COLMAN 14-30 Dual Fd, S/N 1371, ’71 4-Thrd w/Sizing Cycle REF#104BARBER-COLMAN 22-15, S/N 923, ’62 Dbl Thrd, Dbl Cut REF#104BARBER-COLMAN 16-11, S/N 184, ’50 Dbl Thrd w/Vert DRO REF#104BARBER-COLMAN AHM, S/N 1896, ’42 Sgl Thrd w/3 Jaw Chuck REF#104BARBER-COLMAN 16-16, S/N 2745, ’51 Sgl Thrd w/90 Deg Hd REF#104BARBER-COLMAN 16-16, S/N 3171, ’53 Dbl Thrd, Spanish Nameplates REF#104BARBER-COLMAN 16-16, S/N 3580, ’59 Dbl Thrd w/Diff & Auto Hobshift REF#104BARBER-COLMAN 16-16 Multicycle, S/N 3641, ’60 Dbl Thrd w/Diff REF#104BARBER-COLMAN 16-16, S/N 3660, ’57 Sgl Thrd REF#104BARBER-COLMAN 16-16, S/N 4136, Dbl Thrd, “C” Style End Brace w/Diff REF#104BARBER-COLMAN 16-16 Multicycle, S/N 4170, Dbl Thrd w/Jump Cut Cycle “C” Style REF#104BARBER-COLMAN 16-16, S/N 4473, ’73 4-Thrd w/Workclamp Cyl “C” Style REF#104BARBER-COLMAN 16-16 Multicycle, S/N 4520, ’75 Dbl Thrd w/Gooseneck Slide REF#104BARBER-COLMAN 16-16 Multicycle, S/N 4631, ’79 “C” Style End Brace, 4W Adj Ctr REF#104BARBER-COLMAN AHM (36”), S/N 1152, ’42 Dbl Thrd REF#104BARBER-COLMAN 16-36, S/N 4090, ’66 Dbl Thrd, “C” Style End Brace REF#104BARBER-COLMAN 16-36 Multicycle, S/N 4232, ’68 Dbl Thrd “C” Style End Brace w/Diff REF#104BARBER-COLMAN 16-56, S/N 3136R84, ’53 (Reb ’84), Dbl Thrd REF#104BARBER-COLMAN 10-20, S/N 6700045890, ’76 Dbl Thrd w/2 Cut Cycle REF#104TOS OFA Series Conventional Gear Hobbers, 12” & 40” Dia REF#105TOS OHA Series Conventional Gear Shapers, 12” & 40” Dia REF#105

GEAR PINION HOBBERS & SPLINE MILLERS

HURTH #KF-32A 15” Dia, 59” Face, ‘67 REF#103SCHIESS RFW 10S 55 x120” Single Index REF#103MICHIGAN Tool #3237 REF#103

GEAR HOB & CUTTER SHARPENERS (incl CNC)

BARBER COLMAN #2 1/2-2, 2.5” Dia, Straight Flute Hobs REF#101FELLOWS 6HCS, 6” Dia, Helical Shaper Cutter Sharpener REF#101GLEASON 2JST Straight Bevel “Coniflex” Cutter Sharpener REF#101GLEASON 13 Universal Hypoid Bevel Cutter Sharpener REF#101ARTER #A-12, 12” Rotary Surface Grinder for Sharpening Sharper Cutters REF#103BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, ‘57 REF#103BARBER-COLMAN 10-12, 10" Dia, 12" Length, Spark Out REF#103FELLOWS #6SB, Helical Cutter Sharpener, 6” Dia, up to 50 Degrees REF#103KAPP #AS-305GT, 1 DP, 28" Grind Length, 10" Diam., Str. & Spiral REF#103KAPP #AS204GT, 10” Dia, Wet Grinding, CBN Wheels, ‘82 REF#103BARBER-COLMAN #3 HS, Hob Sharpener, 4" Max. OD., 4" REF#103BARBER-COLMAN #4-4HRS, Hob Sharpener, 4" Max. OD. 4" REF#103REDRING MODEL #SGH "PREIFORM" SHAVE CUTTER GRINDER/SHARPENER REF#103STAR 6X8 HOB SHARPENER PRECISION GEAR & SPLINE HOBBER REF#103HYBCO #1900 Tool Grinder REF#103BARBER-COLMAN 2-2 1/2 , 2.5” Dia REF#103KAPP AS-410B REF#103GLEASON #12 Sharpener, 40” Dia REF#103BARBER-COLMAN 2 1/2-2, S/N 16, ’66 Wet w/Auto Feed REF#104BARBER-COLMAN 6-5, S/N 110R, ’55 Wet w/Auto Dress & Sparkout REF#104

fEATUREDSUPPLIERSMidwest Gear corporation — ReF #100Phone: 330-425-4419 • Fax: 330-425-8600Email: [email protected]: www.mwgear.com

Mohawk Machinery, inc. — ReF #101Phone: 800-543-7696 • Fax: 513-771-5120Email: [email protected] Website: www.mohawkmachinery.com

new england Gear — ReF #102Phone: 860-223-7778 • Fax #:860-223-7776Email: [email protected]: www.newenglandgear.com

R. P. Machine enterprises, inc. — ReF #103Phone: 704-872-8888 • Fax #:704-872-5777Email: [email protected]: www.rpmachine.com

Repair Parts, inc. — ReF #104Phone: 815-968-4499 • Fax #:815-968-4694Email: [email protected] Website: www.repair-parts-inc.com

havlik international Machinery, inc. — ReF #105Phone: 519-624-2100 • Fax: 519-624-6994Email: [email protected]: www.havlikinternational.com

MACHInERYContact Gear Solutions at

800-366-2185 to list your machinery.


BARBER-COLMAN 6-5, S/N 396, ’66 Wet w/Auto Dress & Sparkout REF#104BARBER-COLMAN 6-5, S/N 433, ’69 Wet w/Auto Dress & Sparkout REF#104BARBER-COLMAN 10-12, S/N 643R83, Wet w/Auto Dress, PC Control, Fact Reb ‘83 REF#104TOS OHA Series CNC Gear Shapers, 12” & 40” Diameter REF#105 TOS OFA Series CNC Gear Hobbers, 12” & 40” Diameter REF#105

GEAR SHAPERS CNC

36” Shapers, 14” Throat Risers, 53” of Swing, Qty 3 REF#102FELLOWS #10-4/10-2, Qty 150 REF#102HYDROSTROKE #50-8, Qty 2 REF#102HYDROSTROKE #20-8, Qty 5 REF#102HYDROSTROKE #FS630-125, Qty 1 REF#102HYDROSTROKE #FS400-90, Qty 2 REF#102FELLOWS #20-4, Qty 6 REF#102FELLOWS #48-8Z, Qty 1 REF#102FELLOWS #10-4 One-Axis CNC (A/B), 10" Dia, 4" Face, 4 DP REF#103FELLOWS #FS-180, 3-5 Axis, 7” Dia, 1.25” Face., 6 DP, New ‘88 REF#103LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#103LORENZ # LS-180, 4-Axis CNC, 11” OD, 2” Stroke, 5 DP REF#103FELLOWS FS400-90 Hydrostroke Gear Shaper CNC Nominal Pitch 15.7" REF#103LORENZ #LS-304 CNC Gear Shaper 5-Axis Heckler & Koch Control REF#103MITSUBISHI #SA25CNC, Fanuc CTRL, 9.84" Dia., 2.38" Face REF#103STANKO /RPM #48-8 Gear Shaper CNC REF#103LORENZ #LS-156 CNC Gear Shaper Dia 6” REF#103RP-GS 1250 CNC Max Dia 12”, Face 11”, 2 DP REF#103RP-GS 800 CNC Max Dia 9”, Face 8”, 2.5 DP REF#103RP-GS 400 CNC Max Dia 7.8” Face 8”, 3 DP REF#103SCHIESS RS-20 S REF#103FELLOWS #20-4 20” Dia, 4” Face, 4DP REF#103FELLOWS FS400-125, 16” Dia, 3.5 DP 5” Face REF#103FELLOWS #10-2 CNC REF#103

GEAR SHAPERS

FELLOWS #3, 3” Dia, Fine Pitch, w/Change Gears REF#101FELLOWS #7125A, 7” Dia REF#101FELLOWS #4AGS, 7” Dia REF#101FELLOWS #10-4, 10” Dia, 4” Face REF#101FELLOWS #10-2, 10”Dia, 2” Face REF#101FELLOWS Z-Type Horizontal, 18” Dia, Change Gears, Nice REF#101FELLOWS #36-6, 40” Dia, 6” Face, 6” Riser REF#101FELLOWS #36-6 Spur/Helical, 36” Dia, 6” Face, w/Vari Helix Head REF#101 FELLOWS 100” Dia, 8” Face-Width, Change Gears, Extra Guide, Gears REF#101FELLOWS #10-2, (10” Dia), 2” Face REF#102FELLOWS #10-4, (10” Dia), 4” Face REF#102FELLOWS #4A Versa, 10” Dia, 3” Face, 4 DP, New ‘70’s REF#103FELLOWS #8AGS Vert Gear Shaper, 8” Dia, 2” Face, 6-7 DP REF#103FELLOWS #10-2, 10” Dia, 4” Face, 4 DP REF#103FELLOWS #20-4, 20” Dia, 4” Face, 4 DP, ‘70’s REF#103MAAG #SH-100/140, 57” Dia., 12.6” Face, 2 DP, Internal Attachment REF#103FELLOWS #3-1, 3” Max Dia, 1” Face, Pinion Supp, High Precision REF#103FELLOWS #48-6 INTERNAL GEAR SHAPER ONLY,0-72"OD,6" Face REF#103FELLOWS Model Z Shaper, 5" Stroke, 17" Bore in Table, ‘50’s REF#103LORENZ #SJV00, 7” Dia, 2” Face, ‘50’s REF#103MAAG #SH-100K 47”/12.6”/1.7 ‘60’s Internal Attachment REF#103MAAG #SH-150, 57" Dia.12.6" Face REF#103MICHIGAN #18106 SHEAR-SPEED GEAR SHAPER,14" DIA,6"FACE 4 DP REF#103PFAUTER #SH-180 Shobber 7" capacity hobbing, 9.45" cap REF#103FELLOWS #36-6 Max Dia 36” 6” Face, 3 DP REF#103FELLOWS #7, #7A, 715, 75A,, 7” Dia, 0-12” Risers, Several Avail REF#103FELLOWS #HORZ Z SHAPER, 10 x 6 Dia 27.6 Face 8.5” REF#103MAAG #SH-75C, 30”/8”/2.5”/’52 REF#103MAAG NBP 40 REF#103FELLOWS #6, #6A, #645A, From 18”-35” Dia, 0-12” Risers REF#103FELLOWS #10x6 REF#103MAAG #SH-600, 235” Dia 36”, 1DP REF#103FELLOWS #4GS & 4AGS, 6” Dia, 2” Face, 4DP, ’68, Ref.# Several REF#103MAAG #SH-180-300, REF#103SCHIESS #RS-20, 12”Stroke REF#103MAAG #SH-350/500 REF#103TOS OH-6, Dia 19.7” REF#103SCHIESS #RFW-10-S REF#103TOS OHA50 CNC 5 20” Dia 5” Face REF#105

GEAR DEBURRING/CHAMFERING/POINTING

CROSS #75, 10” Dia REF#101REDIN #24, 28” Dia, CNC, Twin Spindle Deburring Mach, Yr ’90 REF#101 REDIN #18, 20” Dia, Twin Spindle Deburring Mach REF#101CROSS #50 Gear Tooth Chamferer, 18” Dia, Single Spindle REF#103CROSS #75 Gear Tooth Chamferer, 10” Dia, 10” Face, ‘52 REF#103

REDIN #18, 28” Dia, 2, 3, 4 Spindle, Deburrer/Chamfer, PLC’s, Tilt Table REF#103REDIN #20D, 20” Dia, Twin Spindle, Deburrer/Chamfer REF#103SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14” Dia, 5” Face, ‘82 REF#103SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10” Max Dia, (3) New ‘96 REF#103HURTH MODEL# ZK-5, Twin Spindle, 12” Dia, Two Spindle REF#103REDIN #24 CNC Dia 4” Setup Gear Deburring REF#103 CROSS #54 Gear Deburrer, 30” Dia, 18” Face REF#103CROSS #55 Gear Deburrer, REF#103CROSS #60 Gear Tooth Chamferer, 10” Dia, Single Spindle REF#103FELLOWS #100-180/60 CNC Max Dia 180”, Single Spindle REF#103CIMTEC #50 Finisher REF#103RPM #GC-500 CNC 20” Dia, Single Spindle REF#103RED RING #24 Twin Spindle Dia 4” REF#103

GEAR HONERS

Fassler #K-400 CNC Hone 16" Dia REF#103Fassler K-400A CNC Hone 16” Dia REF#103Kapp #CX120 Coroning 4.7” Dia REF#103Kapp #VAC65 Coroning 10” Dia REF#103Red Ring #GHD-12 REF#103Red Ring GHG REF#103

GEAR SHAVERS

RED RING #GCY-12, 12” Dia, 9” Cutter-Head REF#101RED RING #GCU-12”, 12” Dia, 9” Cutter-Head REF#101KANZAKI #GSF-400CNC5, CNC, 16” Dia, 10” Cutter-Head ‘90 REF#101 RED RING #GCU-18, 18” Dia, Crowning REF#101RED RING #GCJ-36/60, 60” Dia, 12” Cutter-Head REF#101 Fellows #4 Fine-Pitch REF#103Kanzaki #GSP320 CNC 2.6" Dia REF#103Nachi GFG Shaver-5+1 Axis REF#103Nachi Raso CNC Shaver REF#103Red Ring #GCX-24" Shaver REF#103Red Ring #GCU-12 REF#103Red Ring #GCU-8 Shaver REF#103Red Ring #GCY-12 REF#103Red Ring GCI 24 REF#103

GEAR GENERATORS, STRAIGHT BEVEL

GLEASON #710, 10” Dia, Coniflex REF#101 GLEASON #14, 24” Dia, Coniflex w/gauges, gears REF#101OERLIKON #K4A, 60”/90” Dia w/Templates, Crowning, Gears REF#101GLEASON 645 Hypoid Generators REF#103GLEASON #37 Str. Bevel Planer, 6” Dia REF#103GLEASON #54 Str, Bevel Planer, 60” Dia REF#103GLEASON #104 Angular/Straight Bevel Tester REF#103GLEASON #496 Straight.& Spiral. 7.5” Dia REF#103GLEASON 726-Revacycle REF#103GLEASON 725-Revacycle REF#103GLEASON 2A, Coniflex Straight Bevel REF#103GLEASON 14, Coniflex Straight Bevel REF#103GLEASON 24A Straight Bevel REF#103

GEAR GENERATORS, SPIRAL BEVEL (HYPOID)

GLEASON #16, 16” Dia Hypoid Spiral Bevel Gear Generator REF#101GLEASON #26, 36” Dia, Hypoid Spiral Bevel Gear Generator REF#101GLEASON #106 Hypoid REF#103

GEAR GRINDERS CNC

HOEFLER #H-650/800, 36” Dia, CNC w/On-Board Inspection, New ‘98 REF#101 GLEASON # 130, 36” Max Dia, CNC Curvic Cplg, Comp Reb REF#101HOGLUND, Model #264, CNC Internal Gear Grinder REF#103KAPP #VAS-482 CNC GEAR GRINDER, 11.8" SWING DIA REF#103NILES ZSTZ 06-800 CNC REF#103NILES ZSTZ 08-800 CNC REF#103RED RING #SF-500 CNC Int/Ext, 26” Dia, 30” Face, 2 DP, ’88 REF#103REISHAUER RZ300E Electronic Spur/Helical Gear Grinder, 11.8" Dia REF#103GLEASON/TAG – 400 REF#103GLEASON Phoenix 200G Hypoid Grinder CNC REF#103REISHAUER RZ-801 CNC, 31.4” Dia REF#103

GEAR GRINDERS

MAAG #HSS-30A, 11.8” Dia, Spur REF#101REISHAUER #AZA-K, 13” Dia, SPA Diamond Disc, Taper Grinding New ’79 REF#101REISHAUER RZ-300E, 11.8” Dia, Diamond Disc Dresser, Shift – New ‘85 REF#101SHG-360 OKAMOTO, 14” Dia, FAESSLER DSA, Crowning, New ’74 REF#101DETROIT GEARGRIND GGI-16x3A Internal Gear Grinder REF#101

MICHIGAN DETROIT GG-10x24A, 10” Dia, Ext Gear & Spline Grinder REF#101REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#103RED RING #SGJ-18, 18” Dia., 9” Face, Internal Attachment, New ‘78 REF#103DETROIT Gear Grinder #GGI-16x3A, Internal Gear Grinding, 16" OD REF#103HEALD/CINCINNATI #2EF73 Internal Grinder REF#103HEALD, #272 Sizematic ID GRINDER REF#103NILES ZSZT-35 139” Dia REF#103 CINCINNATI –CHOMIENN RC REF#103HEALD, #273A INTERNAL GRINDER REF#103MAAG SD-32-X REF#103NILES 630-CSP REF#103GLEASON #463, 15” Dia REF#103NILES ZSTZ-10, 49.2” Dia REF#103REISHAUER ZB, Gear Grinder, 27" Dia, 11” Face REF#103

GEAR RACK MILLERS/SHAPERS

MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#103SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, ‘80 REF#103SYKES VR-60 Vert Rack Shaper, 60” Cut Length, 4DP, Stroke 4” REF#103

GEAR THREAD & WORM, MILLERS/GRINDERS

WMW HECKERT #ZFWG 250 X 2000, 19.6” Over Bed, 19.6” 78.7” Hob Length REF#103LEES BRADNER #LT 9"x 54" Thread Mill, 9" Dia, 54"Length REF#103J&L #12x45, Thread Grinder, 12” OD, 45” Length, ‘75 REF#103LEES BRADNER #HT 12x54, Dia 12” /54” REF#103MOREY-SHIELDS THREAD MILLER, Dia 12” REF#103BARBER-COLMAN #10-40, 10" Dia., 40" Length, 4 DP REF#103EXCELLO #31L, External Thread Grinder, 5" OD, 20" Grind Length REF#103EXCELLO #33 Thread Grinder 6” Dia 18” Length REF#103EXCELLO #35 and #35L Thread Grinder, 84" Between Centers REF#103EXCELLO #39L Int. Thread Grinder, 9.5" Max Dia., 10" Max. Swing REF#103HURTH #KF-33A Multi-Purpose Auto-Milling Machine 88” REF#103LEES BRADNER #HT12x102, Extra Large Capacity REF#103J&L AUTOMATIC THREAD GRINDER, 6" X 36", ‘38 REF#103HOLFER PROMAT 200 , 7.87” Dia, REF#103MITSUI-SEIKI GSE-50A, 20” Dia , REF#103LEES BRADNER #HH-144 REF#103LEES BRADNER #HT 12"x 144" Thread Mill, 12" Dia, REF#103

GEAR TESTERS/CHECKERS (incl CNC)

GLEASON 13, Universal Angular Bevel Tester REF#101GLEASON #17A, 90-Degree Hypoid Bevel Tester REF#101FELLOWS #12M, 12” Dia, Involute REF#101FELLOWS 600RL, 24” Dia, Roll Checker REF#101David Brown #24 Worm Tester REF#103Fellows 12H Gear Tester REF#103Fellows #12M Gear Tester REF#103Fellows 20M Gear Tester REF#103Felows #24 Involute Measuring Instrument REF#103Gleason/Goulder IL600SV REF#103Gleason #4, #6, #13 and #17 Testers REF#103Hofler EMZ-2602 Int/Ext Gear Tester 102” REF#103Klingelnberg #PFSU-1200 Gear Tester REF#101Klingelnberg #PFSU-1600 Gear Tester-2001 REF#103Klingelnberg PWF-250 Tester REF#103Kapp Hob Checker WM 410 REF#103Maag #ES-430 Gear Tester REF#103Maag #SP-130 Lead and Involute Tester REF#103M&M CNC Gear Tester #3515 REF#103M&M CNC Gear Tester #3012 REF#103National Broach Gear Tester GSJ-12 REF#103Oerlikon #ST2-004 Soft Tester REF#103Parkson #15N Gear Rolling Tester REF#103Parkson #42N Worm Gear Tester REF#103Vinco Dividing Head Optical Inspection REF#103Fellows #24H Tester REF#103

MISCELLANEOUS

WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80” Centers, 12” Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965 REF#100TOS SU & SUS Series Conv Lathes REF#105TOS SUA Series CNC Flat-Bed Lathes REF#105GLEASON #529 Quench, 16" Diameter REF#103VERTICAL TURNING LATHES AND MORE - Please Check Our Website To View Our Entire Inventory REF#103

Just as its name implies, Wind Systems magazine will address all aspects of this booming industry, providing information pertinent to landowners and managers, site developers, maintenance workers, economic development professionals, construction companies, tower and component-parts designers and manufacturers—in short, everyone involved in the systems central to and surrounding wind power generation. Brought to you by Media Solutions, Inc., publishers of Gear Solutions and Venture magazines.

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windsystemsmag.comViSiT US AT AWEA’S WiNDPoWER 2009 BooTh #2516


abUndanT manUFacTUring, inc. 820 cocHran STreeT • STaTeSville, nc 28677

PHone: (704) 871-9911Fax: (704) 871-9961

email: [email protected]: www.abUndanTmFg.com

gear grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27” diameTergear Hobbing . . . . . . . . . . . . . . . . . . . 84” diameTer 36” Facegear SHaPing . . . . . . . . . . . . . . . . . .120” diameTer 8” Facegear SHaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24” diameTer

abUndanT — geAred To ServICe your NeedS!

GEAR GRINDING SERVICESGear cutting from raw material to finished parts

Ground tooth gears and pinions to 1 D.P. and up to AGMA quality class 13

From 1” Diameter, 64 D.P. to maximum sizes listed Max. Face Max. Size Max. Pitchspur gears 24” 92” P.d. 1 d.P.

helical gears 24” 72” P.d. 1 d.P.

spur & helical gears, crown hobbed 22” 72” P.d. 1 d.P.

internal gears & splines 8” 100” P.d. 1-1/4 d.P.

ground gears, crowned or straight 20.5” 72” P.d. 1 d.P.

herringbone gears, center grove 14” 36” P.d. 2 d.P.

2182 E. Aurora Rd., Twinsburg, OH 44087Phone: (330) 425-4419 • Fax: (330) 425-8600

www.mwgear.com • E-mail: [email protected]

(248) 601-8145 FAX (248) 601-0505Email: [email protected] www.colemfgsystems.com(248) 601-8145 FAX (248) 601-0505Email: [email protected] www.colemfgsystems.com

APRIL 2009 49

manufacturing excellencethrough quality, integration, materials, maintenance, education, and speed.

mArKETPLACE

Now HiriNg(Statesville Chamber’s 2006 Industry of the Year)

3 years minimum elecTrical macHine Tool experience, Fanuc conTrol experience, Traveling required.

• Machine Tool Mechanics

• Machine Tool Electrical Panel Builders

• Machine Tool Mechanic Trainee

• Machine Tool

Builder Trainee

• machine Tool Field Service Technician

— must have own tools— Three years experience

preferred — High school education or

ged required — overtime required

— must have own tools— Some experience preferred— High school education or

ged required — entry level Position— overtime required

APPly in PErson or sEnd rEsuME To [email protected]

r.P. MacHiNe offers coMPetitive wages, beNefits, 401K retireMeNt aNd relocatioN

costs oN all PositioNs

We Manufacture Broaches & related

tooling for any Broach Machine

Broach houseMfg., inc.™We Have Used Broaches In Stock

11383 Route 166 • Marion, Il 62959618-993-3530 • fax:618-997-9158

e-mail: [email protected]

Sharpening or reconditioning alSo production Broaching

We Weld Broken & Chipped Broaches

FELLOWS 70-15 GEAR SHAPER 105” Dia. • 70” Pitch Dia. • 15” Stroke CapacitySPECIALTY MACHINE — ONE OF ONLY A HANDFUL IN THE WORLD!

affect the ability to hold tolerances, and these collets are often disposed of.

Many people don’t know that collets can be resealed for a fraction of the cost of new ones. resealing collets will extend its life while also protecting the arbor or other tooling from prema-ture failure. in the process of having your workholding supplier reseal your collets, the collet runout and concentricity should also be reconfirmed, insuring maximum tooling performance.

Arbors and mandrels: over time arbors, mandrels, and collets become worn and develop runout or lose the ability to grip the parts correctly. runout not only negatively affects spindle time, but it also increases setup time and affects part quality. arbors, mandrels, and collets can be reground or chrome plated and then reground. This process will return the components to like-new condition. small costs that will reduce set up time and improve both production and profitability. applying an abrasive coating to the gripping surface of fixturing can increase wear resistance and transmit more driving force to the part, reducing slippage and improving performance (fig. 8). out-of-tolerance hydrau-lic arbors can be unassembled and have only the worn parts replaced. in addition, hydraulic arbors that no longer expand can often be repaired by replacing seals and recharging.

Chuck and fixture refurbishing and re-engineering: as with smaller components, whole chuck assemblies and fixtures can be refurbished. Missing print dimensions often appear as an impediment to assembly refurbishing. We find that many people are unaware of the extent to which an experienced workholding supplier can help them through re-engineering. often customers are frustrated when critical dimensions are omitted from their tooling prints. This can create problems when they have a work-holding component, like a collet or even an entire fixture that needs repair or a replacement made. it is especially problematic in the case of foreign products where cost and delivery can play a larger role. This can be frustrating when price and delivery are crucial. an expert workholding firm can recreate missing print dimensions, and even produce new replacement parts from a handful of broken parts where no print is available. This can save the day for many customers, and in the process also pro-vide an additional or backup supplier.

protect what you HaveFixturing: proactive fixture maintenance is a given in any economic environment, but right now maintaining the maximum toleranced functioning of workholding fixturing is crucial. it seems rudimentary, but we see a lot of issues that could have been avoided by a thor-ough cleaning, and especially cleaning chips out of the activation angle area. fixturing represents a substantial investment, and pro-tecting this investment through regular maintenance will pay many dividends. regular maintenance will provide optimum part holding and part location, giving you optimum production. here are a few tips:

• clean fixtures after use. This sounds simple, but it’s the single most important part of maintenance.

• lubricate fixtures after cleaning. This will prevent rusting, as well as allowing smooth operation of the fixture.

• store fixtures in a clean, dry location.

Collets: custom collets range in price and complexity. They are stable units but are frequently highly tolerance. here are a few pointers to make collets last longer and maintain maximum precision (fig. 9):

• store collets in lined drawer or containers. avoid letting them roll around or knock up against each other.

• Take care not to drop collets. if a collet is dropped it should be visually checked to be sure it is not cracked or bent, and then checked for runout at installation.

• reduce operator error by marking collets clearly. consider color coding collets and posting laminated instructions for chuck assembly and part loading.

• examine collets regularly for wear, and reseal when necessary.• and, of course, never activate a collet fixture without a part in the

fixture.

planningThere are some experts who believe that when the economy recov-ers it will do so rapidly. even if the overall recovery is not rapid, depleted inventories will need to be replenished across the board. Demand will increase, and the manufacturer who can respond quick-ly will pick up market share from the suppliers that haven’t remained forward thinking. our large oeM customers are telling us that when the economic landscape improves they expect things to get hot and hectic, and we will all be expected to respond accordingly. future planning to maximize capacity and growth at the end of the current economic tunnel is essential. Taking stock now, and planning capital expenditures to dovetail with lean-type processes such as reducing batch sizes and shortening lead times, will allow suppliers to seize upcoming opportunities. planning now for workholding that is inter-changeable, versatile, and expandable will provide the production agility that will be even more important in the recovery.

Fig. 9: Simple steps extend collet life

AbOUT ThE AUThOr:ann pettibone is ceo of Drewco Workholding. To learn more call (262) 886-5050, send e-mail to [email protected], or visit online at [www.drewco.com].

< Continued from pg. 44

�0 gearsolutions.com

APRIL 2009 �1

ADvERTISERINDEX

COMPANY NAME PAGE NO.Abundant Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Allen Adams Shaper Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Allied Sinterings, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39American Gear Manufacturers Association . . . . . . . . . . . . . . . . . . . . . . 27Arrow Gear Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18AWEA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31B & R Machine and Gear Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . 25Barit International Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Bourn & Koch, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Broach House Manufacturing, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Butler Gear Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Carnes-Miller Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Circle Gear & Machine Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Cole Manufacturing Systems, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Colonial Tool Group, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Drewco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Encoder Products Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,36Gear Manufacturing, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,49Hanik Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51High Performance Gear, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44HobSource, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Hydra-Lock Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Innovative Rack & Gear Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48J. Schneeberger Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29James Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14KAPP Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ka-Wood Gear & Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49KH Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14KISSsoft USA, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Klingelnberg GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Lawler Gear Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Micro Surface Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Midwest Gear Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Mitsubishi Heavy Industries America, Inc . . . . . . . . . . . . . . . . . . . . . . . BCMohawk Machinery, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Moore Gear & Manufacturing Company, Inc . . . . . . . . . . . . . . . . . . . . . 43New England Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7P&G Machine & Supply Company, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . 48Precision Gage Company, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Process Equipment Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2R P Machine Enterprises, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,15,49Raycar Gear & Machine Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Repair Parts, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Riverside Spline & Gear, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Russell Holbrook & Henderson, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Stock Drive Products/Sterling Instruments . . . . . . . . . . . . . . . . . . . . . . 16Stor-Loc Modular Drawer Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48The Broach Masters, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBCThe Company Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49The Gear Works—Seattle, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48TMFM, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Toolink Engineering, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IFCTSA America, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Ty-Miles, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Walker Forge, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Wind Systems Magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

www.hanikcorp.com

CORPORATION

t

�2 gearsolutions.com

GS: Could you tell us a little about the company’s history?RO: of course. The company was founded by Walter schneeberger in 1923 to manufac-ture tool grinders for profiling woodworking and molding cutters. We are headquartered in roggwil, switzerland, with subsidiaries in germany, france, italy, great britain, china, and the united states. schneeberger was pivotal in the development of the first cnc controlled profile grinders, which were intro-duced in 1985, and it launched the world’s first five-axis tool grinder into the market in 1990. our elgin, illinois, facility was incor-porated in 1994 when it became clear that the service and application demands were such that we needed direct representation here in the states to handle installation and training. We do work through sales repre-sentatives—we’re represented by some 20 agencies around the world, in fact—but if we’re talking about something like the gear-manufacturing industry, the technology is very specific, so we do work closely with our representatives to handle those aspects of the relationship. We also send our techni-cians back to switzerland for a minimum of two weeks of recurrent training each year, and we host technicians from the home office quite regularly. our dedicated sales staff also has a strong grasp of the technol-ogy involved.

GS: Describe the grinders you manu-facture, especially those of interest to gear manufacturers.RO: our aries model is an economically priced four-axis cnc hob and shaper cutter

SALES MAnAgERJ. SCHnEEbERgER CORPORATIOn

roberto’CoNNorQ&A

FOR MORE InFORMATIOn:call (847) 888-3498, send e-mail to [email protected], or go online to

[www.schneeberger-us.com].

sharpener that’s ideally suited for sharpen-ing straight hobs and cutters, which do not require complex wheel profile dressing. in addition to a generous work envelope and a ge-fanuc control, the work is typically held between centers in a very comfortable, ergonomical fashion on a t-slotted bed. We offer an extensive line of five- and six-axis cnc grinders such as the corvus gDs with five-axis grinding for oversized tools and the corvus bba for grinding broaches. The gemini model also offers five-axis grinding for both tool regrinding and production, and it was designed for automated high-per-formance tool production. our production machines can be outfitted with integrated robotic handling as well as the galileo opti-cal measuring machine. We can also config-ure the machines to provide different direct drive spindle horsepower ratings of up to 56 hp for coarse pitch hobs and spindle speeds up to 18,000 rpM, and also to provide automatic in-machine cnc wheel dressing. our cnc machines utilize a touch screen with a Windows Xp platform driving ge-fanuc controls with our own menu-driven, graphical, Quinto software. other options and peripher-als include integrated optical measuring sys-tems, integrated laser wheel measurement systems, and automated coolant filtration systems. The integrated optical measur-ing system allows the user to compare the actual with the desired profile, which is an option that’s very popular in europe, where this level of automation is in heavy use. our longtime expertise in this area, through work-ing with our customers globally, is invaluable here in the states as the interest in profile automation is growing.

GS: Is all the manufacturing conducted in Switzerland? If so, what do you stock?RO: yes, it is, but we usually have two or

three machines in stock. We have an aries on the floor, at present. The grinding applications best suited for the aries are typically less complex than the other mod-els, so we can quickly configure them for prompt delivery. With the larger machines the integration work is typically handled at the plant, but our lead time is generally around six months, which is very competi-tive. We do carry an extensive inventory of spare parts, ranging from electronic parts to rebuilt spindles for prompt replacement.

one thing we’re quite proud of is the solid foundation incorporated in the design of the larger models. These are massive, heavy duty, stable machines, as we start with an advanced polymer concrete bed and make extensive use of linear drive motors and glass scales, which very much differentiates us from companies that are still relying on relatively outdated technolo-gy. add schneeberger monorail linear ways on the horizontal axis and water-cooled spindles for thermal stability and you have an accurate, flexible, dependable machine. but what it really boils down to is hav-ing a solid machine foundation, because you’re not going to get the highest-quality grinding unless you have that solid, stable platform.

“Schneeberger was pivotal in the

development of CnC controlled profile

grinders in 1985, and launched the world’s first

five-axis tool and cutter grinder in 1990.”

For Return Information, Fax To:205-380-1580

0409_gearsolutions

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