download the july/august 2003 issue in pdf format

Thanks to Eli breakthroughmonolithic column design, anof these usee benefits are [lOWavailable, and much more.

New 600HTT TURBOT~STER performs fasterCNC roll testing of spiraland hypoid bevel gear sets.

Bevel gear cuttingenters a new era withthe Phoenix" IT 275HCCNC Bevel GearCutting Machine.~t's 35% smaller than the Phoenix-175HC butproduces parts withdiameters up to 275 mm... cutsdry without chip shrouds andvacuum ysteras ... s.impJifiesami peeds part loadl unload andcutter changeover; .. and featuredirect-drive pindle motors forfaster setup and machining times.

It features a smaIl footprint, ergonomicandeasy-to-use design." performs not onlybasic pattern checking but also 8FT (SmglcFlank Transmission error) testing and

SBN (Srructure-Borne-Nolsejtesting ... andaccommodates workpiece diameters up to 600 rum.

The 600HTI TURBO TESTER- also shares the sameplatform made popular with the recent introduction ofthe 600HTL TURBO LAPPER-, so you benefit fromvast reductions in floorspace, and a highly acce: sible

work. chamber.

IGleaso'n 'Corpo~ati:on100) UniversityAve.,PO. Box22970

Rochester, NY .1.46017-.1282U.S.A.Phone: 585/473-1,00) Fax: 585/461-4348

Web site: www.gl.eason.oom Eemail: [email protected]

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JULY/AUGUST 2003 The IoumalofGear ManuJac.turing _

GEAR EXPO PRE-SHOW ISSUE

115

FEATURES

Sho,w BasicsThe Who., What, When and Where of the Gear Indu try's Main Event. 15

Expo Exhibitors took. for Economic UpswingInterview with exhibitors .'17'

S.h-w-t~---e, Ad;v~rtorialsosopp f ... 1. _This special section features. some of the majorexhibitors who will be at 'Gear xpo 21

411

DEPARTMENTS

Veg,etab'I,e-Based Oil as a IGearLubricantA study on different formulations and their effect on gear wear 28:

Design 'of High Contact Ra.tiol Spur Gears Cut wi,th Standard Tool!sUsing 20 pre ure angle 1001 to generate high contact ratio 34

Comp'any Profile: Arrow Gear Co.The past and present of one of theworld's leading piral bevel gear specialists 41

IOn a P,ossible' Way ,of S:ize ,and WeighllReduction of al Car Trans~missionMinimizing hob idle distance to reduce shalt size in clustergears 44

56

Cover photo courtesy ofTbe Timksn Co.Canton, OM

PubHsher~s Page'Shade of Gray , 7'

RevolutionsFriction welding and a new gear manufacturing method 9

Industry INewsWhat's happening in thegear industry 26,

Technicall CalendarDon't mis the e important upcoming events 38

ln MemoriamDark Dudley, 19:17-2003 , 39

Advert,iser IndexUse this directory to gel information fast 5,11

Plr,oduct NewsThe latest products for the gear industry 82

Classifi.edsServices, Help Wanted, Web itesand more 54

AddendumTo Climb A Mountain. A Railroad Needs Gears 56

-..tJ1nnl1I.aI gear arfneW.Integrated dreulng unit, aIIowI generat.Ing and form grinding with dreasableand CBN tools in the same machine,with a capacity of 200/300mm dia. andup to an Bmm module. Combined withthe automatic loading! unloading fea-ture, this machine is an efficient produc-tion unit with proven Liebherr reliability.

Tho Geanng Part ... 00t.p of Utbho",Kllngelnberg and Qerllolmn

Liebherr Gear Technolog-yCo.1465 Woodland DriveSaline, Mil 48176-1259734.429.7225 [email protected]

Gear' Holblbingl ShaIPiin'gl 'Grindliingl Mleasuri;ngSEE US AT GEAR,EXPO 20(l~ BOOTH 1# 1400

mailto:[email protected]

==~~=::flnlla8fementArrow's latest success was utilizing ourstate-of-the-art technologies to design thegear tooth geometry and to manufactureall bevel gears in the PTO& AGB forPratt & Whitney's PW 6000 engine.

2301 Curtiss Street Downers Grove. Il 60515Tel: (630) 969-7640 Fax: (630) 969-0253

www.arrowgear.com

S:EE US AT G,EAR:EXPO 2003 BOOTH # 933

SEE US AT GEAR IEXPO 2003 BOOTIHI# 9H

IEDITORIAL

Publisher & Editor-in-ChiefMichael Goldstein

Managing Editor William R. Ston

Associate Edltor Joseph L. Hazelton

AssistoJl.llEd.llor Robin Wright

Editorial Consultant Paul R. Goldstein

Technical EditorsRobert Errichello

Don McVitlieRobert E. SmithDan Thurman

ART

Arl. Director Jean Bartz

ADVl:RTilSING

Advertising Manager Patricia Flamdvertislug Cocrdinator Carol Tratar

i{~[RCULATIONI

Circulation Coordinator Carol Tratar

INTERNET

Web Developer Dan MacKenzie

Gear .Industry Home PageHI SalesPatricia Flam -

RANDALL PUBLISHING STAF:F

PresidentVice President

Ace.oooting

Michael GoldsteinRichard GoldsteinDianne Borg

Phone: 847-431.66ME-mail: p{[email protected]

Web: www.geartechnotogy.comwww.powertransmission.eom

BPA,W

VOL. ZO. NO ...CEAII, TECEI OLOC}'. Til. Journal or CearManu[o. [I.. ond a' O.,'he precesses described in GEAR TECHNOLOGY conformtc sound engineering practice. Neither ~he authors nor l.bepublisher can be held responsible for ifijurLes sustained whilefOIJOWll1g [he procedures described. pUillmllster: Sendaddress changes In GEAR TECHNOLOGY_The Journal ofGeM MOJIu(oclUri.g. 1425 Lanr Avenue. P.O. Box 1426. elkGreve Village. fl. 1\0007. OConlenl< cnpyrighled by RAN-DA-.lLPUBLISH] G. INC.. 2003. No pan of this publica-tion may be reproduced or transmitted in an), form or by on)'means, electronic or mechanical, Includ ing photocopying,f~ordjng. or by any informetion stOFl1SC and retrieval sys-(em. ~ilhoUl permissicn In wridn~ from the publisher,Conrents orad.. are subject 10 Publi.her-< approval.

4 JULY/AUGUST 2003. IGEA'R iECillNUIWGY www ..geartechfl%gy.c.om. www.,powertr.aflsmissio'n.,com

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Ball or pin contacts _Shaft and ring-type parts _

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Statisd.cal packages available _

Looking for an easy, cost-effective way to check gears? Marposs hasthe solution - the M62 bench gauge system. It's accurate, flexibleand right .at home on the shop floor:ND more dedicated gauges .The modular M62 system is quickly re-toolable using ordinary handtools. You'll save time and the cost of dedicated gauges.A single-source for all of your gear inspection needsNo one has a more complete line of gear checking equipment thanMarposs, so every component is guaranteed compatible. Forgetmixing and matching.If you are looking for easier, more accurate gear checking plusoptional noise detection, take a look at the Marposs M62 benchgauge system. It's geared just for you .

~~~!!~IIM62 Double FJank Gear RoUerManlJailoading of gear wheels and! gear shaftsMeasures: Radial. composite deviation Radial runout_ Tooth to tooth radial composite deviation

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_ Optional noise detection.All functional checks can be displayed on therugged. E9066 industrial PC system which olfersa linear graphic display with full SPC functions

Gear Masters/Gauges Go-no go gauges_ Thread gauges_ Spltne gauges_ Plain masters and master gears

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PUBlJISHER'S PA'GE

Shades of GrayInAmerica and most parts of the world, people are looking ] Traffic on powertrans-for answers about what' going to happen next in the manu- mission.comT'

For More Information,. Contact:American Gear Manufacturers Association Phone: (703) 684-0211 Fax: (703) 684-0242 E-mail: [email protected] Website: www.gearexpo.com

SEE US AT IGIEAR EXPO 2003 !BOOTH#800

Greater Columbus Convention CenterColumbus, OhioOctober 5-8, 2003

mailto:[email protected]://www.gearexpo.com

_------------1 REVOLUTIONS _

evaluate the weld integrity. ares '10 B. pre-determined peed, its motor

A~ ILxJe is being friction welded to = Mandan!- All of thi excluding the post run .is dis ngaged and the workpieces areized bub-like,endl. Photo CODI'IU1' of.Amelican te: ting, takes from five seconds 10 sever- forced together under forge force. As theFriCtiOll1 'We'I'ding, Inc~ al minute ..When factoring lin. the testing, spindle. peed. low the kinetic energy

wWW.powBTtr,BlIsmission.com'. www.gssrtschnology.,com GEAR TIECHNOLOG,V JUlV/AUGUST 2003 '9

'We,lding Different Gear MateriallsFriction welding bas been thought of

as a olutian for customers with lot ofvolume to be welded and 1.01 of capitalinvestment, Industry opinions are chang-

ing. though, and it's becoming an eco-nomic option for small-volume batches.

The proce s has been around forawhile but. has neverbeen as popular asother conventional mean, of welding.Unlike traditional welding. frictionwelding can join both similar and dis-imilar materials with different mechaai-

call , nd physi ::IIproperti s Ihrough rota-tional force and hydraulic pressurewithout flux or filler material. Good can-didate materials for these combination

are carbon and alloy . reels,Among the gear industry applications

are bi-metaliic propeller haft for themarine indll try. plined axle hafts. and:!langed gear blanks.

In addition, friction welding lakeplace in a narrow, heat-affected zone, I)

it hll minimal effect on adjacentmachine or heat treat characteristic ,says Joel Don hue. general manager ofAmerican Friction Welding.

The job . hop, located in Brookfleld,

Wl, has offered lhi .ervice for year ,

rno Ily on hydraulics, pump shafts, elec-tric motor hafts. drills, and. hand tools.a wen as automotive and con Lructionequipment

Whatever the product is, once itarrives at American Friction Welding,the welding process starts with the prod-uct' axi of ymrnetryIt' ea ie I. whenthe component have a. natural axi ofymmetry; If' a part i. not al'ready

equipped with this. then engineers devel-op the tooling 10 create one.

After the axis of ymmetry i deter-mined, weld parameters are developedwhich include rpm. axial load, timeframe. and amount of axial shortening.After developing these parameters, partsare then. tested in. a . ituation thai mimic.it actual performance. Once thoseparameter are establi hed and proven,

they're loaded into the machine' COIl- Itroller. Then they begin the proces of!loadi.ng parameters and feeding cornpo- j

nent before commencing production. IThe machine controller m nitors those ;

e.l. parameter and. t~eir limitations Iithroughout the production run, If any-thing falls out id the parameters,themachine sends out an alert. I

One workpiece i held in a rotatingpindle and the other i held in a station-

ary clamp . Operators control the speed ofthe motor-driven workpiece. Then. anaxial load is applied tothe componentsbeing welded, Interfaces of the twocom-ponents rub together, re ulting in heat

Thi i maintained until a predeter-mined amount of time or axial horten-ing occurs. At this point, a braking force

i applied and the axial load i increasedin 'the final forge pha e. Thl force i heldfor a pre- et am uru of lime after therotation stops,

Many lime. a post-weld te t i doneon a ampling basis as the final step tocheck for torsional, bend or hardnessproperties of (he heat affected zone. In

a.ddition. ukrasonic inspection is II ed to

Welcome to Revolutions, 'he col-umn' that brings you the latest most

up-Io-date and easy-to-rBad infor-

mation about ,the people Bnd tech-

nology of the gear industry.

Revolutions welcomes your sub-missions. Please send them to'GearTechnology, P.O. Box'426, ElkGrolle IVillage.. It ,fi0009, fax (841)431-6618 Dr B-ma;1 [email protected]. If you'd like' mor"infonIlat;on about any of the ani-

des that appear; plellS8 use RapidReader Response at www,geBrtech~-nology.comlm.ldm.

the initial weld development process canlast from a few hour toa few weeks,

depending on pan. size. shape and con-

figuration.As tar as capabilities. American

Friction Welding has eight. direct-drivefriction welding machine ranging fromfour to 125 tons. which can weld soliddiameters from ]/8"-4 1/4".

"One machine has pari orientation. Its

spindle has an end coder on the spindlethat keep track of where the pindletart and Lop ," say Donohue "The

advantage of this feature i that the com-ponerns can have uniquely machinedfeatures with a relationship '10 one anoth-er atter welding wi.thin +/_.1.5." Thiskind of control is a major benefit to thdirect-drive welding proces .

However, there's another type of fric-tion welding called inertia welding.

Manufacturing Technology Inc. in SouthBend. IN. does both and points out dis-tinctive a pect .of each approach.

Inertia welding uses flywheels boltedto a pindle chuck. The : pinene aceeler-

http://wWW.powBTtr,BlIsmission.com'.

RE.VOLUTIONS

stored in the rotating mass dissipates as Iheat through friction at the weld inter- jface. The welding force continues to

pushthe two' components together for ashan period of rime after the rotationcea es,

Though it offers the operator Jesscontrol,inertia welding generally has

fa ter cycle times, a narrower heat-

affected zone and fewer weld variabtes

(rpm and pressure) and doe not requireclutches and brakes, says Kevin Grewe,sales engineer for MTI Welding.

"For gears, there's not a definitemethod that's better than the other.Sometimes there's the need 10 orientateone gear onto another and, :in that case,the direct drive friction welding is best,"

SEE US AT GEAR EXPO .2OOl BOOTH # 820

he says. "We do slightly more inertiawelding, mainly because auto makerswant such high cycle times."

Friction welding, whether done by

inertia or direct drive, is not a elationfor every company or application. Manytimes, the component configuration andmaterial type are good indicators ofwhether the process is a good fitGenerally, free machining and resulfur-ired material, which contain high lev-

els of lead and sulfur, may have adverseeffects on the joint. say Donohue,

For Kuhn Knigh; Manufacturing Inc.of Brodhead WI, tile fricaon weldingprocess was a perfect fit. Hugh Hosely,a buyer for tile company, hired

American Friction We.ldmg everalyears ago to friction weld Kuhn' plugas embly product ,

"We've been very happy with theservice," he says, "it's inexpen ive and

produces a better product becau e twopieces become one, Ai 0, with alradi-tional weld.they're only held together bya ring of weld, and this is far superior."

No P,itch ICones. N:o IFaceCutters = Greater Gear

FreedomDavid Dooner wants more freedom

for de igners and manufacturers of spi-ral. bevel and hypoid gears, He wants togive it to them by removing the gears'restrictions on face width, spiral angleand! number of teeth,

He also wants them to be free to spec-ify those gears with. the same proceduretbey use to specify cylindrical gears,

VariableDiamatflf

Clltter

IllypoidIPinion

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face cutters fromilie design and manu-facture of spiral bevel and bypoids.

Dooner has been working on this waysince the late ]9805, when be was a grad-uate tudent at 'the University of Florida,'Gainesville. Studying for his doctorate,Dooner ianed to think about unifyingtile design and manufacture of differenttype of gears, 1,1 ingtheir kinematic struc-ture to create a single framework.

He discussed his idea with his doctor-al advisor. Ali Seireg, and it became partof his doctoralmesls, It also provided thefoundation of his method for spbalbevels and hypoids.

After receiving his doctorate, Doonercontinued to work on the method, collab-orating w:ithSeireg until Seireg's death inSeptember. Today, Dooner is an associateprofes or in the mechanical engineeringdepartment atthe University of PuertoRico-Mayagiiez.

To this point, his method remains the-oreticfll-"It hasn'tbeen developed."

Dooner say it, hasn't been because:"First, the mathematical relation hips areDot immediate." and "Second, there is awell-established art, with an enormousbase."

He adds that most people are focusedon improving the existing method-"There's been I,iule effon to developingnew ways."

Dooner, however, has been focusedon getting rid of pitch cones and face cut-ters 'to create a new way.

He explains: PitcJil cones are a designtool for spiral bevel and bypoid gears.While helpfal, the cones restrict the facewidth of those gears.

With Dooner's way, the gears wouldbe designed using mathematical formulasthat compare the spiral bevels andhypoid with their theoretical ideals. Thatcontrasts with today's practice of com-paring them with the ideals thai can beobtained 'through manufacture.

Dooner says using the theoreticalideals gets rid oflbe re tncuon on piralbevel. and hypoids' spiral angle andnumber of teeth and may get rid of theirlimit pressure angle.

During manufacture, face cutters ofspiral. bevels and hypoid create teem ofincreasing thickne s as they move acrossa gear's face.

Dooner's cutters, though, would belike variable diametergears with cuttingteeth. They'd cut like variable diameterhobs, so they'd compensate for varyingtooth thickness. The compensating

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would remove restrictions on face widthand spiral angle. Wi.thout fuce cutters,number of teeth wouldn't be restricted,either.

Dooner says cutting piral bevels andhypoids would become like bobbingcylindrical. gears, so specifying themcould become like pec.ifying cylindricalgears. Tooth profile, pressure angle, spi-

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REVOLUTIONS

ral or helix angle. face width-theycould all be used to design and manufac-ture spiral bevels and hypoids.

According to Dooner, the cutterscould even be used to manufacturecylin-drical gears. Different cutters would stillbe needed to manufacture differentgears---coar er pitch cutters for coar erpitch gears, finer for finer, bigger cuttersfor bigger gears, smaller for smaller-

but the cutters would be the sametypeand could be u ed in the same type ofmachine.

Dooner says his machine and cutterswould streamline a gear manufacturer'smachine tool facilities while makingthem more flexible in the types of gearsthey could create.

According to Dooner, his methodwould provide several other benefits.

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First, gear manufacturers would be ableto create lead crown and profile relief intheir spiral bevel and hypoid gear sets atthe same time they're cutting them.

Second, they might not need to lap,burnish or polish the sets. Dooner says iflapping. burnishing or polishing wasn'tneeded, gears and pinions would be inter-changeable. If one broke, a gear manufac-turer could replace just that member of ahypoid or spiral bevel gear set: he would-n't have to make an entirely new set.

Third, his method would offer newalternatives in gears through its greaterdesign flexibility, For example, spurhypoidal gears-not possible in today'smanufacture-would be possible.Dooner describes spur hypoidals asnon-inter. ecting, non-parallel gearswhose teeth go into and come out ofmesh all at once.

Moreover, Dooner simulated theirmanufacture and saw his method couldeven make spur hypoidals more effi-

cient by reducing their sliding contact.Spur hypoidal gears could be used ill

rear axles of antornobiles ..Before benefits, there'd have to be

development and testing. Both are pos-sible, though. Dooner's work is at atpoint where a machine and set of cut-ting tools could be developed for test-ing. He doesn't know how much moneyit would take to create them, but hedoubts it would be an unusual amount:"How much would it take to develop anexisting machine?" 0

Tell Us What You Think ...Visit www.gelfr.chn%gy.comto Rate this column Request more infonnation ContaClIhe people or organization lI18IIIioned IMake a suggestionOr call (847) 431-1i604 to talk to one of our edi-tors!

112 JULY/AUGUST 2003 GEAR UCHN,OI.OGiY www.geartechnology;com wWW.pOw81tlIJIISmission.com

mailto:[email protected]://www.geartechnology;comhttp://wWW.pOw81tlIJIISmission.com

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_------------GiEAR:EXPO.2003------------1111Columbus Gear Expo-In the

Heart of Manufacturing WorldAGMA's Ge., Expo 21m isrecognized n die worldwide gear eventl

October H,_Greater Columbus Convention Center. Columbus. OH

Buyers and senln of gllrs, IIIchine tool .. cutting tools, servicisand odIer IUPillilrs to thlgHr industry coagreglt8 i. Collllllbus!

135 Exhibitors 38,000 Squire Feet www.g .... xpo.com

AGMA official hope to ell compa-nie on attending Gear Expo based onthree factors-location, location. loca-tion.

The bi-annueltrade show will be heldDel. 5-8. at the Greater ColumbuConvention Center in Columbu , OH.Detroit. MI. has traditlcnaljy been theguaranteed venue for half of the GearExpos because of its reputation as theautomotive capital of the world.Alternating shows rotate between otherMidwe tern eitie . Gear Expo 'OJ washeld in Detroit and Gear x.po'99 in

a hville, TN.According to AGMA vice pre ident

Kurt Medert, the Columbulocationhould prove to be an ideall choice

because of i.1 centralized location. Whilea hville wa too far outh for many

companies 10 send representatives.Columbus is within driving distance ofthe world's gear manufacturing centers,

"The cily that constantly does well isDetroit," be say ,"But with Columbu ,60% of our audience lives within 500miles,"

Nurnerou manufacturing companiesare located within the Columbus metro-politan area itself and can make a day tripof Gear Expo. For example. Honda Motor

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HOTELS,Gear Expo exhibitors and attendees can take advantage of speciall AGMA fates, butonly by booking before September 9, .2003. Published rates are for single/double occu-pancy. Mention reservation codes indicated below to tab advantage of the discountl

Hvatt Regencv Columbus ConventionCenter-SUO350 N.lHigh St, Columbus OIH43215Telephone: 16141463-1234Fax.:{61412803034Code: AGMAThefullservice, 6OO-room hotel is direct-ly connected to the convention center;For more information, visitINWW. columbus, hysft. com.

Crowne Plaza Downtown-$12933 Nationwide Blvd., Columbus OIH43215Telephone: {6141461-41ooFax: (61414611-2679Code: AGMAAlso cnnnaetad to the convention center,it has 400 rooms and suites. For moreinfo, visitW\\W cmhdowntown. crownepfaza, com.

Hampton Inn & Suites 115501 N. High St. Columbus OH 43215Telephone: 16141559-2000, ,(800)426-7866fax: (6141559-2001Code: AGMISelect-service hotel located directlvacross the street born the conventioncenter. For more information, visitwww.hamptoninn.com/hi/cofumbus-downmwn.

Courtyard bV Marriott Downtown-$l1Q35 W. Springl St, Columbus I1IH43215Telephone: (61412283200, (8001321-2211Fax: (6141228-3266Code: AGMNLocated three blocks south of conventioncenter. but within walking distance of sev-eral restaurants. For more info, visitlNWW.c/Jurtyard.com/cmhc,{.

IRed Roof Inn Downtow-n-$HIO1!11E. Nationwide Blvd., Columbus OH43215Telephone: (,614)224~6539,1[8001733-7663Fax: (614) 2284037Code: AGMIASituated across the street from the' conven-tion center. This select-service hotel has150 sleeping rooms and su i~Bs, VisitWWIIY.redroo"comlor more information.

Drury Inn & Suites Convention Center-$9988 E. Nationwide Blvd . Columbus OH 4321'5(6141221-1008, ,[8001378-7946Code: 545068Connected to the convention center, thehotel has 180 rooms and suites. For moreinformation, visit the web site atwww.druryhoteis.com.

http://www.pow,erfrB'DSmin;QI1'.com.http://www.druryhoteis.com.

ISO 9001 Certified

T:RANSMECANICA

RapidDelivery.

PreciseProfiles.

Custom Bevel Gear Mfg.Per your Sample and/or Blueprint Specs

=,BsII:.:=:-.~~_~. ----=-- ----'lI;~Machine and Gear CorporationSharon. TN

Spiral neve} Gears~- ,66" PDStr,aighl Bevel GearS': 80" .PDSpurs, Hellcals, Spline ShaftsGearbox RepairHeat Treat ~ RCm. ,-In-House

~

BREAKDOWN SERVICES

18002380651 Fax 731456.3073

SEE US AT GEAR ~PO 2003 BOOT!H# 9115

____ GEAlR EXPO 2003, _

Columbus by Inight skyl'ine ..as viewed from the highway. Courtesy of theGreateT Columbus, Convention & Visitors BlII'eIlll. Photo' by R.ad Berry,

Co. Ltd. has several plants in the area. and Columbus is closeenough for Kentucky companies [0 drive up for '!he day.

In the current economy. closeness call be all asset. because itwould enable attendees who Live in the Midwestern or orne ofthe Eastern states to drive to Gear Expo. Columbu i approx-imately seven hours driving distance from Chicago. threehours from Pin burgh. and 12 from Des Moines. Show goerswho arc in a greater hurry can take advantage of the summerair fares or lase booking rates. Cheaper airfare are expectedcloser to the show date. and AGMA has et aside a block ofhotel rooms al special rates Ie ee box). Hotels are all cpproai-matelya ten-minute drive from the airport and cab fare shouldrun Ie than $15.

Regardless of how they get (here. Medert expect Gear Expoattendees to be impressed with tile show's facilities.

The Greater Columbus Convention Center was recently

expanded with unlimited floor load restrictions, which is anoth-er reason it was the ire selected. (Becau e of the heavy equip-ment normally brought to the show. Gear Expo cannot be heldat facilities with restriction of less than 350 pound per quareinch.)

Also. there are 3() restaurant within five 1.0 W minutes'distance of the show. 0

Tell Us What Vou Think ...Visit www.gflBrtechlll1/ogy.comlo Rate this column Request more information Contact thl companies mlntioned Mike a suggestionOr call {847143'1-6&04to talk 10 one of our editorsl

116 JULV/AUGUST 2003- GEAR: TECHNOLOG,V '. www.geartechno'logy.,com www.powertr,aRsmissio'n,com

http://www.gflBrtechlll1/ogy.comlohttp://www.geartechno'logy.,com

!GEAR EXPO 20031 ----------------------------- -

Expo Exhibitors Look forEconomic Upswing

IIompanies in the gear industryare looking for igns of an eco-nomic upswing as they preparefor Gear Expo 2003,:lIld ev-era) are eeiag uch a. ign,

The ign i quoting."Quoting activity has been heavier

starting in the firsl quarter," ays DaveMelton, expo irion /cemmumcarionsmanager for ,Gleason Corp. of Roche ter,NY. "We are eeing products are beingquoted, but because of tile war [in Iraq],[purchases] are being pushed back."

Quoting is also up at ContourHardening Inc. in Indianapolis, IN.Quoting has increased for its contractprocessing and heat treat systems.

"Wbich would be a prell}! good indi-cation that something's getting ready tobust loose," says Contour's vice presi-

deru, Michael R.. haplin,In Alexandria, VA. Kurt Meder!, vice

pre ident of the American Gear Man-utacturers Association (AGMA), addhe' been hearing generally po itive talkabout business among gear manufactur-ers and uppliers through everal recentas ociation meetings.

At American Metal. Trealing Co.,though, Bruce Devney is talking to gearmanufacturer and isn't hearing encour-aging news. ,,- lobody is talking rightnow about any rosy projections for thenext six months." says Devney, presidentof the Cleveland, OH-ba ed company.

David Good fellow, pre ident of SUAmerica Inc. of Hoffman Estates, Il.,says, "We're hoping there will be somekind of resurgence in the gear industryby that time."

That time i Oct .. 5-8, when theAGMA will hold Gear Expo 2003 inOhio, at the Greater ColumbuConvention Center.

But, with the economic slowdown,Meltonexpects expo attendance to bedown. Devney agree: ..~ expect fewerattendees, traffic should be slower-maybe even less exhibitors."

Goodfellow notes, though, the expois in the heart of the Midwest=-Illincis,Indiana, Iowa. Michigan, Ohio andWisconsin-which is a "fairly substan-tial gear industry territory."

For a sense about attendance, GearTechnology surveyed people at 20 com-panies who werepotential expo atten-dees. The survey was informal, so itsresults aren't representative. Still, of 20companies, [I replied they'd be sending

The city ,a~Columbus,. OH, will be ham., 'to IGear Expo 2003. which will be, held 'Oct 5-8. {Ph 010 courtesy 01 N'ation,widslnS1uram:e.)

Iwww ..powe't,ao'smission,c,om. Iwww.g1e.g,'s'chno.togy.com GiEAR lU;HNOU)GlI' '. JUILY/AUGUS1200J 1J

Process Gear has been a'leader in the custom gearlindustry since 1942. ProcessGear is capable of producinqparts up to AGMA Glass 12with the documentation andprocess control that comeswith M&MC Precision Gearanalysis. Customer appli-cations range from powertransmissions, constructionequipment, HVAC,. hydraulicpumps and printing tradeequipment

Benga' Industries is aprecision custom injectionmolder specializinq in gearsand 'engineered plastic parts.Bengal serves a wide varietyof markets including auto-motive, medical, industrial,HVAC and children's prod-ucts,

Process Gear3$O-T North Rivllr RoadSdJilier Park, fl60176(847)671-1631Fax (847) 67Hl840lI'WW.processgear.oom

Bengallindustries11346 53n! Street NorthCleaIwater, FL 33760(127) 572-4249fax (727) 573-2428lI'WW.trengalinduslries.com

&onlacl: ih ert!@processg:ear.'CDmI

_______ GEAR EXPO 2003 _

In Columbus, more than 130 'gllar-industry of'oanizlltio!1s. will exhibit at Gear Expo 2003. tPhoto 'COUf-tesy of Rod Berry.'

at least one person to the expo.N one of the people surveyed, though,

replied that he'd be looking at machin-ery with the possibillty of buying,

Still, Melton expects attendees to be amore focused, serious crowd, "They'llbe looking hard at what new technolo-gies are out there," the Gleason managersays, "They' H be more serious buyersthan tire kickers."

Serious buye.rsare what AIWSystems Co, got at Gear Expo 2001 andare what it's hoping for again. "We pmb-ably got 12 to 15 good solid leads thatturned into customers," says RossDeneau. vice president of manufacturingfor AJW, located in Royal Oak, ML

AfW is one of what seems to be theindustry's "fortunate few." The slowingeconomy hasn't touched the cutting-toolcompany-c-=Our particular ca e. it'snever slowed!down," Deneau says.

He explains A/w's repair workincreased a lot-"When the economyslows down, people look to repair[more] than to replace." More recently.Deneau's seen increased buying of newtooliog .. After all, products eventuallywear out.

And Gear Expo is a chance to look atnew products.

Star Cutter Co. of Fannington Hills,Ml, and SU America will feature their

lines of gear-related products, consoli-dated through Star-SU Inc, and dis-played in their shared expo space. Thespace will also-feature Star-S I'S line ofFellows gear shaper cutting tools, aswen as a Fellows gear shaping machinefrom Bourn & Koch Machine Tool Co,of Rockford, IL.

In its space, Gleason will exhibit its245 TWG. a threaded wheel grindingmachine, and tile GMX 275. an analyti-cal gear tester, The GMX i first in a newseries of analytical gear te ters jointlydeveloped by Glea on and Mahr GmbHof Gottingen, Germany,

AJW win display blades (bolll car-bide and high speed steel). cutler bodies,hobs, shaper cutters and other products.AfW expectsto feature its alliance withKlingelnberg Oerlikon TechnologyCenter (KOTC) of Saline. ML The twocompanies will keep separate spaces atthe expo, though.

American Metal Treating Co, willdisplay an induction hardening processfor internal gears. The eNC process calltreat internal gear: with outside diame-ters up to 30 inches and diarnetral pitch-es from 2 to 6.

Contour Hardening will exhibit adua1-fl'equency hardening process thatcan send. low and medium frequenciesand radio frequencies through one coil,

18 JULY/AUGUST 2003 GiEAR nCII!NOWGY www.gearlec.bnol,ogy.co.m- www.p,Qwerlran.s.mission.com

http://www.gearlec.bnol,ogy.co.m-http://www.p,Qwerlran.s.mission.com

New Business Alllie's Combin'eIExpo Spaces

lUke the com,panies 01 Sigma P,ool. several newly ,aUied busi-nesses willi have ,combined spaces at 'Gear ExIPO2003.

The ailliedilbusiinessu are: Star ICuner Co. and SU Amer,ica I,ne.,Bourn & IKochIMachine Tool CD.,andSU Amer;ica,and Gleason Corp.and IMahr GmbH.

.At Gear Expo,2001. Bourn & Koch omRockilor,d. Ill; Star Cutter 'ofFannington Hills, MI:andl SU America ollHoffman Estates, IL, occu-pied their ownspa.ces .AI Gear Expo 2oo~, they'n occu,py 'one 3:,200-square-loot space.

This ,combiningl comes from two, alliances. The.irst consolidat-ed the' gear-re'lated 'product lines of Star Cutter and SU .America.ICr,eatedin ,early 21Kt2,.healliiance resulted iin aljoint ,company.Star-SU Inc .for selling HIe ,consolidated lines.

The second amance was between Bourn & Koch and! SUA_mericaviul the gear-related product lines ,ofdefunct fellows ,Corp.

founded in 1896" Fenows manufactured gear shaping machinesand ,cuttingl tools (r,om its headquarters in North S,pringf,iel'd.VT. OnIF,e'b.. 13. 2002, Fellows ceased operations as iits Iparent ,company,IG.oldmanIndusb'ial Grou,p.filed for Chapt,ern bankruptcy.

By summer 2002', Fellows' manufacturingl assets had been soldand split between Bourn & Koch, which acquired the assets relat-ed to, gear shaper machines. andStar-SU. whi,ch acquired theassets, "elated to gear shaper cuttiingtools.

Tbetwo comparues. also agreed Star-SU woulld be r'Bs,ponsible,for promoting', representing and selling Boum & Koch-built fellowsgear shapers thr,ough Star-SUIand Bourn & Koch distribution chan-nels,

IDa.vidiGoodfenow, SU America~s president. says this ,expo willbe iii chance for previous fellows customers to be reintroduced to,Fellows Iproducts, whic'h ha,vebeen par(jy redesigned ,andIre-engi-neered.

Reflectingl anotber alliiance. GI!eason of R:ochescer, NY. willshare, its 2,-500-sq,uare-footspace,with Mahr of Gouingen. Germany.In 2001. Ma'hr .arranged with lGIeason to, use Gleason~sG-AGE soft-ware 'on Mahr's IPRI~AR form and gear measuring machine.

Their partnership soon became much more extensive. At thestart of 2002, Gleason became the sales and support agent forMahr's g,ear metrology produclsaroundi the! Wlldd. The IProductsincluded the gear-speeiJicversion ,ofMahr's PRIMAR;ma.chine.

Gleason and Mallr al:so started to, iointily deve'lop new gearmetrologv products, which would be sold under the brand name"meason Mahr.U llater in 2002. the, tw,o' companies introduced theGMX 275,. the first in a new series of analytical gear test,ers from thejoint anangement. 0

EGT!

GEAR TECHNOLOGYIS NOW

AVAILABLEONLINE

FREE to Oualifii,edR'e.aders Anywher,e in

the WorldAn enct duplicat,e of every issue,including all Ihe articles. d anddepartments, available online atwww.goartschoology.com.

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'-----------------------

http://www.goartschoology.com.http://www.geartechnology.com.http://www.geartschnology.com

_----------- 1 OEAH IEXPO 200-3 _

Be ides new products, Gear Expo is achance to talk,

ot surprisingly, exhibitors expecttalk in the aisles to be about the econo-my.

Devney expects the "aisle talk" toinclude the continuing movement ofgear manufacturing overseas to easternEurope, mainland China and India.

Chaplin expects talk about the econo-my too. but he adds people will also betalking about quoting activity in theirown companies and what it means.

Goodfellow says he expects talk toinclude gear manufacturers themselveshaving more chances to quote gear jobsfor the automotive and truck industry asit continues to outsource more of its

A!IN Systems Co. announcesthat it is now amanufacturing source 01 spiral gear roughingand finishing cutters and bodies.

We also can manufacture new spiralcutter bodies in diameters clS'through 12"at present.

AIW can also supply roughing and finishing', cutters for most 5"-12" diameter bodies.

II Whether it's service or manufacturing, con-I sider us as an alternative source for cuttersI and bodies.

You'll be in for a. pleasant surprise.

NEW! Hob and S'haper Cutler Resharrpeningis now ilvllilab'I'e atA/W Sy.stems. Company Royal Oak, Michigan 48067

Tel: (248) 5443852 Fax: (248) 544-39221111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111I1111111111111111111111111111111111111111ml11111, 11-

SEE US AT GEAR: EXPO 2DO~ BOOlTH ## 1111

manufacturing,As of June 3, the AGMA had 135

exhibitors set to occupy more than38,000 square feet of space inColumbus' convention center. In 2001,Gear Expo had 192 exhibitors who occu-pied 57,000 square feet.

Medert, however, says many compa-nies are waiting until the last minutebefore deciding whether to exhibit. Headds they're waiting in the hope thatthere'll be an economic upswing.

Despite them. Medert say : "Overall,Lexpect the same high-quality showwe've alway had."

Besides U.S, companies. the expowill host exhibitor companies fromAustralia. Canada, the Czech Republic,Finland, Germany, India, the People'sRepublic of China. Spain. Switzerlandand Taiwan. Other non-Ll.S, companieswill be represented through theirAmerican operations. such as MitsubishiGear Technology Center of Wixom. MI.and SU America.

In three months, these and otherexhibitors will gather for the gear indus-try's trade show. By then, the possibleupswing that several see may be an actu-al upswing.

As Goodfellow says: "We're hopingthat. there's some sense of recovery bythen," 0

I TeU Us What You Think ...1 Visit www.g8llrtechnology.comto

Rate this column Requestmore infonnation Contact the companies mentioned Make a suggestionOr call (847)437-6604 to talk to one of OUf edi- .tors!

20 JULY/AUGUST 2003. G:EAR TECHNOLOGY. 'W'Ww.gs.alts'chao.logy,com www.pow.ertransmission ..com

http://www.g8llrtechnology.comtohttp://www.pow.ertransmission

PORuss'eill. H,ollbrolok& IH'endersonBooth Number.: 313

IProduct LineAs a leader in the fine-pitch gear tooling mar-ket. our Hne 01 TRU-VOLUTEhobs, shaper cut-ters and gear metrology products are recog-nized for the highest Quality and: precision lin!he industry ..

lOur products provide the superior Quality andaccuracy you demand. lOurlocus continues tobe on the importance of quality tools, inspec-tion methods and gear technologies, which are'essential to first-class gear manufac"Ming.

ICompanv Profile'Established in 191,5, Russell, Holbrook &IHender.son, Inc. has since' been providinginnovative products and solutions to the geartooling .industry.

Our parent company, Ogasawara, PrecisionLaboratory L~d.,Japan, is. a world leader linfine-pitch gear tool manufacturing, and relatedproducts.

ICon1actRussen. ltilo'lbrook & tilenderson. Iln,c.for the latest in our TRU-VOLUTE amduetupdates,. related articles and events cal'endar,please visit our online website at:http://www.truvolute.com

Our sales and technical service. can bereached at the following lceaticn:Russell, Holbrook ,!Ii Henderson, Inc.A Member of Ogasawara Group17-1'7 Route 20B North, Fair Lawn, NJ 07410Telephone: (20117965445fax: '[2011796-5664http://www.tru-volule.com

"Gear Tool SohJti;ons"www.powertr,ansmiss;on.com. www.gesrtechnology.com. GEA.R TECHNOlO'GY. JULY/AUGUST 20113 21

-

S H 0 WST 0 P PER S ADVERTISINGSECTION--------

J.RM lnternatlenal .Inc.610111ndustriall Av,enu,eRockford. IL. 61111Phone: (815) 282-'9330Fax: (81'5) 282-9150E-!Malil:: [email protected] Site: www.jrmintemationai.com

Booth Number: 538;

IProduct llineJRM International, Inc. has been a distributor of German and American machlnetocls and acces-sories. sinceI9B4. Burka-Kosmos supplies. grinding wheels for ali makes and models of thread-type, profile and g.enerativa gear grinders. James Engineering is a builder of gear deburring,chamfering and washing machines. Schrem hydraulic locknuts are designed lor ,clamping alltypes of tools and:workpieces. WEKO Gear Technologv is a supplier 01 CNC ins.peclion machines,mac!"ne service and rabu',ld/retrofit '{ou can also talk to tine people Irom Kesel about their rackmilling machines. Visit us at booth number 538.

J.RM Inte'rnationa/, In'c.

IMarposs Corp.IBooth Number: 1115

Need to Check Ge,an?Looking for an easy, cost-effective way to checkg,ears?The Marposs M62 bench gauge system withoptional noise detection is accurate, easy to use andQuickly re-toolable using ,ordinary hand tools. You'lIsave time and the cost of dedicated gauges. With theM62 you can measure: Radial composite deviation Radial runcut Tooth to tooth radial composite deviation Tangential composite deviation Nicks.aptional measurements include center distance, bore

diameter ami perpefldicularit'/of bore to gear face.

All functional checks can be displaved on the ruggedMarpass E9066 industrial PC system that offers a lineargraphic display with full SPCfunctions.

JIRM Internationall, line.

Contact

MARPOBSJ300 Cross Creek.ParkwayAuburn Hills, MI ,l1li326-27581-888-6277611 1-248~370IM04Fax: 248~37D0G2'11IE-mall: [email protected] ..cDm.

http://www.tru-volule.comhttp://www.powertr,ansmiss;on.com.http://www.gesrtechnology.com.http://www.jrmintemationai.commailto:[email protected]://www.mulloss

GEAR EXPOI

S H 0 WST 0 P PER S ADVERTISING SECTION

Booth Number: 111

Description:We will have on display a selection oI cutter bodies and blades, We will havestraight bevel cutters, coniflex cutters and stick blades. ~HSS& carbide} We' willhave bore giage5and height gag,e5.We will have hobs, We will have an assortmentof diamond tools tor hard turning and dressing. We will havekeyseat cutters anddove tails on display. We willi ha,veCBN and diamond plated wheels. We willi alsoha!y,e an assortment of hardware,

Contact:A!W Systems'6U E. HarrisonRoyal' Oa'k, MI48067Phone: (.2,4815443852Fax: (24815443922

OIl Kaiser Diamond 'Dressiing ToolsBooth N!umber: ,218

Product 'Line01. Kaiser Diamanrwerbeuge, located in Celie, Germany, specializes; ill the design and manutsc-ture of precision, rotary diamond dressers forthe gear industry. Or. Kaiserprecision diamond prod-ucts are ClIlsurpassed in qUality, accuracy, and innovative design.

Corn,panv P,r,ofjll'eOr; Kaiset provides dressing solutions for continuous generating, single tooth, spiral, bevel, gear,and plunge grinding applications in both natural and polycrystalline diamcnd versions. Or..Kaise.rPCOreinforced dressers significantly extend dresser life when compared with standard non-rein-forced direct plated dressers, especially in fine-pitch applications. Or..Kalseroffars quick deliveryand tile highest accuracy at competitive prices. Helappingand raplating services are available.

S.L, Munson & Company!is the exclusive distributor for Or; Kaiser products in North America.

C'ontactS.L Munson&. Company40~Hug,erStreetColumbia, SC29.201Phone: 8007751390Fax: OO~~:929050:1Email: [email protected]

IBooth Number: '933

AJrow Gear to Exhibit a.tGear iExpoArrow Gear Company of Downers Grove, Illinois will be an axhiblter at this year's Gear Expo.

Arrow's booth will contain several polnts of intarestfar visitors to, the show. A. varietyof g.old platedgears will be on dis,playto illustrate the depth oltha company's machining capabilities. To,eornrnuni-cate the full scope of Arrow's operation, an orientation video will be presented. 'In addition, printedmaterials and interactive CD-ROM programs will be distributed,

Arrow Gear produces high ~recision gears and gearboxes for aerospace and commercial markets. Theyhave also introduced advanced computer techniques for the design and development of bevel gears.

Arrow Gearwill be located at booth #933.

aA...R..RO.W...GEAR._C,OMPANY22 JULY/AUGUST 2003 'GEA~RiECHN'OlOGY www.geartech.nology ..com. WWw.powBrtrall'smission.com

mailto:[email protected]://www.geartech.nologyhttp://WWw.powBrtrall'smission.com

G

IBooth Number: ~921

P,r'oduct liineDura-Bar is the only manufacturer ofcontinuous cast iron bar stock in NorthAmerica, and is the largest in the world.Rounds, squares, rectangles, tubes andspecial shapes are supplied through anationwide distribution network. In'herentproperties include' noise ,and vibrationdamping, machinability, .strength, andwear resistance, making our 'bar stock analtsmativs to steel and other metals influid power, gear and other app'lications.New Dura-Bar Plus lisan engineered ironthat machines betler than carbon andallov steels and other grades of continu-ous cast iron. A material of uncompro-mising consistency, ,it allows meta'i corn-ponent manufacturers to machine moreparts per hour, thereby decreasing cvcletime, increasing productivity, and boost-ing profitability.

Dura-Bar1-800-BAil-MILl (221-64551www.du.ra-bar.comsa'l~es@dural-bar.'com

WWW.powflftrBnsm,;ssion.com. WWW.gflBftechnology.,com. GEAR nCHNOLOG,V JULY/AUGUST 2003 23,

SHOW ST 0 P PER S ADVERTISING SECTION

IProduCI, liine'Presrite Corpora,tion's eightpage' color brochure pro-videsan overview of the company'sforgil1g capabilities,and information on its equipment and its three forgingplants. It also identifies il1dustries served and customerbenefits. Prasrita lis equipped with a total of 16 forgingpresses, ranging; in size from 1,300 toms to 16,000 tons.The company also has a stateof-the-art gear lab andsophisticated machining equipment. Prssrita producesminimum-draft. net- and near- net-shape forgings up to3,000 Ibs. and 18 inches in diameter, and provides induc-tion heating capacity for ferrous materials of .28,000pounds per hour.

Pre:srite ICoJporation3665 East 78th Str,ae!.Cleveland, OH 44105-.2048216.441.5990 FAX:216Ml.26411IE-Mail: [email protected] Site: www.presr.irl ...com

Booth Number: 1125

Company ProfileChamfermatic Inc. was started in 1996 with thagoel ofbuildingi the best, easytosetup gear de:burringmachines on the market We have, by listening to oureustamers' needs, accomplished: this; goa.l.

Product LineChamfermatic Inc. oHers a complete line of gear dsbur-ring machines with capaeitias lip to 36 inches in dieme-ter, from manual to' fully automated systems. We alsoincorporate parts washing, along with deburring opera-ticns to remove oil, lapping compound and chips fromyour parts, while adding II rust preventative. All 01 'ourequipment has esstendard; automatic air-operateddoor, oper.ator interface, P:LC. lind a filtration syst,em.Also, they are' elllPortaole'.

OUf customer service response time is second to none.We also offer contract deburring of your gears, alongwith rebuilding all makes and models of gear deburringmachines, making Chamferrnatie a furl-service supplierto the' industry.

Conta,ct

71142 Burden !RoadMachesney Park, IL 61115Mike Magee, Prssidenl

Phon : (8Ui)I636-!iOII2,FalC(8151 636--0075E-mail::[email protected]

http://www.du.ra-bar.comhttp://WWW.powflftrBnsm,;ssion.com.http://WWW.gflBftechnology.,com.mailto:[email protected]://www.presr.irlmailto:E-mail::[email protected]

GEAR EXPO

IBooth Number: 1134

Star-SU olfersa comprehensive line 01 'gsarcutting tools of alll.ypes, including services for:IHobsShaper cutters

I Milling cullersRac'lccotters

, Band saw cutlersP,ro1l1e ,grindingl wbee'ls.el'ectropl'aled CBNIand d~jamond-platedShaving ,cutlersCbamferin,g and debuuillJl toolsChamfer-roUer toolsRollingl and deb!!ning tools for s,proc'lletg,ears

I

Master gearsI Scre,w compressor rotors

Resharpening lind recoating 0' hobs, millingi, cutlers ,andlshaper 'cutlers,

Resharp aning ,otshaving ,cuHersStripping and replatinq of 'electroplated eRN'and diamond-plated grinding wllealsComplete Commodity IManagement Services,(e'MS)Pickup and dlllive'l" :services ,are IIv,ailab'le incertain, area.s:

Visit our website to download our completeprogram of products and find the match foryour Iparticular need.www.slar-su ..comsll'[email protected]

Our partners SU America, Star Cutter and! Bourn & Koch offer a complete line ofI machine tools for 'gear roughing, finishing and

tool sharpening applications.www.suame,ica.c~mwww..stafCulter.comwww.b.llum-ko.r;h.com

See us at AGMA. Gear' Expo, 2DD~.C'olumbus. OIH, lin Booth 11134.

24 JULY/AUGUST 2003 GEAR TECHNOLOGY www ..gearfech.nolo{}y.com '" www.pow6'rtra.nsmissio.n.com

SHOW S1 0 P PER S ADVERTISING SECTION

Booth iNumber.: 9117'

Com,panv:Barit International Dorporation is a one-stop solution provider lor all gear cuttingtool needs, supplying the world's indus-tries with top quality gear cutting toolssince' 1989. We excel in cost efficiency.quality and precision,

ContactProduct Une:.' Gear nabs Worm gear hnbs.' Involute and parallelsplina hobs.' Shaper cutters Broaches.' Form relieved milling cutters.' Sha~ing cutters.' Rack type cutters Straight bevel, cuttersPlease visit our booth for more detailsl DA'RIT INIE.RNATIONAL CORP,ORATIONI

33B4 Commercia'lI AV8'.Northbroo'k. III. ,601)62 liSATel: 847 -212-81'28:fall:B41-2U-821iO,W'ebsit.e.:Iwww.b.lrit..comE-mail: people@baril:com

N,achii IMachiniing Tech,noll,ogy ICO.Booth Numbe:r:: 500

Neehi Machining "J:echnologvCo. represents global' technical innovation and Ileadership in themachine building and tooling industry. Nachi supplies high technology machining solutionsthrough the Nachi-Red Ring brand of machines and tools.

Naehi Machining Technology Co.'s. goal is 10 facilitate processes which optimize productivitywhile maintaining and improving quality.

The exhibit includes a display of loo'is. process examples, and video presentations. Broaching.Roll Forming, Hobbing and Snaving Machines{Tools are emploved to demonstrate manufacturingprueesses for typical work pieces. Work pieces, and manufacturing equipment wlll be availablefor inspection at the show.

Contact

NAtHI !MACHINING TetHNO,",OGY en11500Twenty~Three Mila Road, Macomb,. MII4B1144'l103IP,holle:(586) 263-0100IFax:;'(586)163~4511www.rlBchimlc.com

http://www.slar-suhttp://www..stafCulter.comhttp://www.b.llum-ko.r;h.comhttp://www.pow6'rtra.nsmissio.n.comhttp://Iwww.b.lrit..comhttp://www.rlBchimlc.com

EAR EXPO-

SH'OWSTOIPIPIERS AIlVERTISINGSECTION----- -

Bootih N'umber: 132Grell Allan Company is dedicated to providing gear tools to the finest gear manufacturers in the U.S., Mexico &. Canada. Our product line includes HQBS,GEARSHAPER CUTTERS,SHAVING CUTTERS,MMG CUTTERS,& GEARMllUNG CUTTERS,and OUR SHARPENING FACILITYservices & supports all!he above. Every tool tIlatwe, provide' is 100%guaranteed to meet or surpass your specified requirements.IEvery tool we furnish bsars our name, prev-illlg;to 'lou that WB' will stand behind our tools. We are I,seturing two of the finest gear tool producers in world at this year's AGMA Show in Columbus:DRAGON CUTTINGTOOLS LTD. & TRANSMECANICA g,A.C.L IBothfirms are recognized as World Class Producers of gear cutting tools, which are sold& serviced in Fairview Park, Ohio" by a staff averaging 25years' experience in the gear tool field.'lfyour lirm has yet 10 realizB,lha advantage of Dragon& Transmecanica we need to be introduced. Our booth is #732. Stop by and find out why our customers are happy and why they will ,agrell thatGreg Allen Gear Tools "GENERATE PROFIT."

WWW.110wertrB'nsm;ss;on.com'. www.(JlJllf,t:hno'logy.,co,m. GEAR T,ECHNOLOG,Y JULY/AUGUST 2003 25

Booth Number: 11134su A_merieaoffers a comprehensive lin'B'of gear roughing, linishing: ,andsharpeningequipment including machine tools lor.

Hobbing for dry and wet machiningSpiral bevel gear cuttingl lor dry and wet machiningPr.ofile 'grinding of external and internal gearsContinue us generating gear grindingShllye grinding/honingRoter, worm and broach grindingShaving cutter and master geal-grindingChamfering and deburring

Willi a long history of manufacturing gear cutting toeIs Samputansili has gained aSignificant competency ill applYing;its own machine tools to its manufacturingprecesses.Optians tha1 include an-tile-machine inspection, autamatic dressing nr rebeticautomation are available. We offer economical single purpose or multiple purposepackag,e sollJtions depending on the application need.

C"ontacIJan Thllm..ll.lIiGrag AllIIn 'Comllmry IlndeJl Tllcbno'I'ogillsZ1135, Lor-ill Roadfairviaw Po rk. Db.i 0' ,441Z644Oc331.(10381, fax- ,440-331-05,16,

I

'

Bootih N'umbe:r: BOO

GEAR EXPO is the worldwide gear industry avant, and the only traele show devotedexclusively to gearing. This year the Show will be held October 5~8, 2003, at theColumbus Convemion Center in Columbus, Ohio. The Show is international in scopeand prollides a biennial forum for the B!I!cnangeef information en tile' bread range ofmachinery. supp'lies and services available for the gear manufacturing process. Fromsoftware 10 hardwa,re, from initial design through testing, exhibitors will be availableto discuss solutions to problems esseclatedwith gear manufacturing.

for mol'- information. visit www.glll1UI1f1.com.Dr 'e-maill [email protected].

@'SAMPU I INSILIIVisit our website to download our complete program ofproducts and find !he match for your particular need,We'r,e closer tIlan you may think.WWI'I. [email protected]

Our partner Star-Sll Inc. ,oHerse complete Iline of gearcutting and finishing tools complementing our range ofmachine [email protected]

Sel us at AliMA Expo 2.001, Columbus, DHI,lin IBooth 1134.

http://WWW.110wertrB'nsm;ss;on.com'.http://www.glll1UI1f1.com.Drmailto:[email protected]:[email protected]://www.star-su.commailto:[email protected]

IINIDUSTIRV NIEWS

News in the Gear Industryferem countries included or excluded !under headings of chains, gears. gear- ~boxes and transmissions. I

Previously called the 'Current!iMarket Outlook." this report was updat- I,

ed 10 provide more consistency. accord-

ing to the association's press release. ,I",.Use of the euro provided an opportuni-ty to generate data on the European

fmarket based on official EU sources, t",exi ling Lees Bradner hobbers, A line such as Eurostat,of CNC hobbers based on the 7-VH is The statistical profile is available on 1"",1n the works as well. a CD-ROM for free to current BMPTA

Among the product offering we I member. For ordering information.

contact the BMPTA of Burton-on- Treru, i,:,.::",U.K., bye-mail at ad'[email protected].

New D'ep'artment at Renold IGear iRenold Gear developed a service ,I,:

and repair department that accepts all

Company Revita'liz,es: Lees BradnerGear Hobbers

Industrial Actuation Group ofLimerick, ME, which recently pur-

chased Fayscott Co., has revitalizedtwo product lines: Lees Bradner gearhobbers and Reid precision grinders.

According to its press release, thecompany will focus on rebuilding, re-manufacturing and CNC retrofitting the

machines that have been rebuilt to pe-cific standards and C C hobbers with

options to fit specific customer needs.For more information all Fay call,

look online aI www.jrryscOlI.cmn. Formore information all Lees Bradner hob-bers or Reid precision grinders, [email protected].

New Sales Manager at LepelRichard Detty was appointed sales

manager of the induction heating divi-sion of'Lepel Corp. Detty has more than20 years' experience in induction heat-ing, most recently at Pillar Industries asthe northeast territory'. regional man-ager. Prior to that, he worked forAmernherm as a lab manager andenior applications engineer.

Lepel. headquartered in New York.NY. has been delivering induction heat-ing solutions for 70 years.

IBMPTA Tracks l'ndus1ry'sProduction and lra.de!

A first-of-its-kind report. trackingeach European country's mechanical

power transmission production andtrade data Oil acomparable basis, inter-country and over time, was released bythe British Mechanical PowerTransmission Assoeiation (BMPTA).

The report lists which products djf-

types of worm,. helical and bevel gear

~~:t~~:;.ardles of age or original man- IBased out of the company's facility at i,

M.ilnrow, Lancashire, .K., the depart-i

ment also provides opportunities for 00.- r,'site maintenance and in-site repairs. !plant surveys for planned maintenance !and technical design expertise for all i

i

I!release, ervicelrepair gearboxe under- !

go exactly the same engineering 1.."".'processes as new units, and a compre-hensive running test andleak check iscarried out before pass off, A twelve- Irnoruh warranty is standard for serv- :ice/repair units. !

IPmSpec, a service from Balder i

Electric of Fori. Smith, AR, provide up- Ito-date information and education about

applications and de ign requirements.According to the company' press

IB.aldorEllectlric LaunchesInfo:rrnati;onService

electric motors, drives, motion controland gear products. The web ite can beacce ed at www.BaldorProSPEC.com.

Siix. New F,acil11itiesAcquir1ed byMetallirnprovement Co...

Metal Improvement Co., a sub-sidiary of Curti -Wright Corp.,acquired the assets of six USA ErMEngineered Coating Solutions facilities.

They will operate under the name ElMCoating Services Division of the Metal

Improvement Co., headquartered inParamus. N1.

Located throughout the country, thecompany provides solid film lubricantcoalingsin North America. Each facili-

ty can apply more than UOO differentceatmgs jo impart lubrication, cerro-ion re i tance. 3-Dd certain co melle

and dielectric properties to certain com-ponents.

Industries served by these facilitieinclude aerospace. automotive, electron-ics and the general indu trial markets.

Phii'ladelphia Ge,ar'sTeclmica'lDrawings Available Onl,ine

Customers of Philadelphia Gear canrequest free technical gearbox drawingsthrough a new page on the company'sInternet ire.

Available requests include outlinedimen ion. layout and mass-elastic

drawings. According to the company'spres release, all requests are processedwithin 48 hours.

Customers must provide the unit'sserial number as well as tile order num-

ber located on the nameplate of eachen do ed drive.

Available technical drawings con-

tain information such as dimensions forinput and output shafts and other tech-nical information enabling engineers toensure proper alignment and to resolveunit footprintissues on-site,

I

Send Us Your NewsE-mail: [email protected]

I

Fax: 1~437-6618Mail: P.O. Boll 1426,Elk Grove,lL 61107 USA

26 JULY/AUGUST 2003. GEAR TlECHN'OLOG'f www.gearteclmology.com www.pow,e.rtrBnsmission.com

http://www.jrryscOlI.cmn.mailto:[email protected]://www.BaldorProSPEC.com.mailto:[email protected]://www.gearteclmology.comhttp://www.pow,e.rtrBnsmission.com

II:NDUSTRY NIEWS

Gear Industry Web Irafficthe following charts reflect traffic to dlrea gear industrywebsites, each representingactivity in a different part of lfIe marketplace.

,~gr------------------------------'ww:w.p.owertransmission.com iin Thousand's

20022003'IUt_--------------------------i.u.~0t_-------------------------1~Dr_---------I_~---~~O

Visitors include thoseinterested in buyinggears, gear drives, andother power transmis-sion components.

11IIaUlER B.E88IDNI

-I _ q. IP_ RE1l!811I)

"ctO j--- .......-+t'

Vegetable- Based Oil as aGear Lubricant

IBmis IKrzan and Jloief Vi.zintinSummary

Universal tractor transmission oil (UTI1Q) irnulrifunctional tractor oil formulated for use intransmissions, final drives. differentials, wet brakes,

and hydraulic systems of farm tractors employing acommon oil reservoir. In the present work, the gearprotection properties of two formulated vegetable-based uno oils. one synthetic ester-based UTIOoil,. one synthetic ester gear oil and one mineral-

based UTIO oil are investigated.The data, presented. in this paper, have demon-

strated thai the formulated vegetable-basedUTIO oils nave high lubricity, high vi cosilyindexes and provide equivalent Of-in someaspects-superior gear protection performancecompared with the mineral-ba ed UTTO oil. Thehigh-oleic sunflower oil formulation derivedfrom the genetically modified plant ha shownbetter results than the rape eed-ba ed (canola-based) oil formulation.

IntroductionIt is generally recognized that mineral oil lubri-

cants represent a potential danger in many applica-tions because they are not readily biodegradable

and are toxic. The need for biodegradable and non-toxic lubricants has been recognized especially in

the areas where they can come in contact with soil,ground water, and crops.

Biodegradability is the ability of a ubstance

ia'ble1-iest Oils. JViscosity Imm2ls1 I

Base stock Oil type v4ll"C vlI)(),c VI Oil code ,IRapeseed oil biodegradable uno I 48.8 10.4 209 R

I

High-oleic sunflower oil biodegradable uno 51.4 10.6 2.03 S ISynthetic ester biodegradable gear oil 101 17.8 195 G I

Synthetic ester biodegradable uno 51.3 10.9 211 H IMineral oil UTTO 55.1 9.2 150 M

ilihle 2-Fatly Acid Content In Test Vegetable Base Stocks.Fatty acid content (%)

Base stock Palmitic I Stearic Oleic Linoleic Linolenic OtllBrI

C 16:0 C 18:0 C 18:1 C 18:2 C 18:3Higholeic sunflower oil 4.7 3.7 72.6 17.0 I 2.0!Rapeseedoil 6.1 2.5 49.1 32.2 6.9 3.2

C X:.Y .... fatty acid chain of length X and containing Y double bonds; e.g. C 18:3 is an 18carbon- chain fatly acid with three double bonds.

to be decomposed by the action of bacteria intoC02, water, mineral compounds and bacterial

bodies. Biodegradability is influenced by numer-ous factors, of which the main are the molecular

structure and the chemical properties of organiccompounds and the environmental conditions of

biodegradability, such as the presence of oxygen,

the possible level of nutrition and the pH (Ref. I).Vegetable oils and synthetic esters are the most

common base stocks for biodegradable lubricants.Synthetic oils represent a fairly recent. developmentin the lubrication market. They can be made byreacting alcohols with fatty acid. Synthetic oilsoffer improved performance compared with allother lubricants, but at a price. Both vegetable oils

and synthetic esters are highly biodegradable andreadily available, but vegetable oils occur naturally,have a "greener" image, and are, in general, three

times cheaper. Properly balanced additives cancompensate for low temperature performance andoxidative stability of the vegetable oils and favorthem as the base stock of choice (Refs. 2-3),

A comparison of the simplified chemical struc-tures of mineral and vegetable oils shows great

similarities. The major difference is that vegetableoil is an ester, while mineral oil is a hydrocarbon.

The presence ofthe polar ester group impacts ev-eral propertie , making vegetable oil better than

mineral oil in reducing friction and wear. Thepolar group also makes vegetable oil a better 01-vent for sludge and dirt, which would be other-wise deposited Oil the surfaces being lubricated.Because of these properties, it maybe pas ihletoreduce the amount of friction modifiers. antiwearagents. and dispersants required to formulate veg-etable oil-based lubricants.

The agricultural equipment is ideally suited touse vegetable oil-based lubricants, because theequipment operates dose to the environment The

opportunity exists to create a continuous cyc\ein

which the agricultural equipment is lubricated bythe oil from a plant growing in the field being cul-tivated! by that same equipment (Ref. 2).

Universall tractor transmission oj] (urrO) imultipurpose nil widely used for agricultural, COIl-struction and other off-road vehicles. UTTO oil i

28 JULY/AUGUST 2003- GEAR:TIECHNOLOGiY - www ..gea.rfech.nology.com. wWW.pOWfUlra.nsmission'.com

http://wWW.pOWfUlra.nsmission'.com

Dr: Jozef V1ifintini a prole sor ill (heU"iw'rsily oJ Ljubljallo'smechanical engineering fac-ult and is head of the Celli"for Tribolog)' and TechnicalDiagnostics. His I1IQjorresearch' interests art' I'tg-etable-based lubricants, ....!'Orresistanc 01advanced material, and diagnostics alldprediction a/wear failllPl's illmechanical sy Il'rns. For his

flower base lock is, derived from a genetically spread over 'the flat specimen before eachtest. On doaorat, V;tilllin studi daltered plant and possesses a sigl1ificantly higher the SRV test rig. just the friction coefficient, at p01l'l'r losses in gears.

WWIW.IHI'wfulrsflsm;ss;o'fI,,/:om. www.geIT.tednology ..com GEAR TiECHNOLOG,V JULY/AUGUST 2003 2'9

pecially designed for lubricating the transmi -sions, final drives. wet brakes and hydraulic sys-terns employing a common oil re ervoir. UTIOoil has to meet some specific reqniremems tooperatein agricultural and construction equip-ment. The oil must provide the correct frictionalbalance to' prevent wet brake chatter and to allowsmooth transmission clutch engagement,

At tile same time, the oil must provide 'enoughclutch capacity for ,efficient power transrni '01'1 andenough brake capacity to stop the tractor ina reason-able lime and distance. urro oil mu t also provideufficient antiwear (AW) and extreme pressure (EP)

properties for tile whole transmi ion y tern. espe-cia1]y for the piral bevel ring and pinion gears in theaxle , The AWIEP additives must not be so active asto cause corro ion in the tractor's hydraulic sy tern.where pump containing alloy of copper can bepresent (Refs. 2 and 4).

Rape eed and uoflewer oil are currentlyused in Europe for the fonnulation of thebiodegradable lubricants. In the present work. theantiwear and extreme pressure propertie of for-mulated rapeseed and high-oleicsunflower-basedVITO oils, synthetic ester-based UTTO oil, syn-thetic ester gear oi], and mineral-based VITO oilare investigated on FZG test equipment. Tileselected formulated vegetable-based uno oilwa further te led on the helical gear res trig,

Sample PreparationOil samples. We have formulated two differ-

ent vegetable-based UITO oil for the investiga-tion . The fmt fortnulation is ba ed on tile rape-eed ba e lock, while the second ba e tock is

derived from a genetically modified ul'1lflowerplant with a high oleic content. The arne additivesystem is u ed for both formulation . The proper-lies of these two fully formulated vegetable-basedVITO oils were compared with a commerciallyavailable mineral-based UITO od,a fastbiodegradable synthetic-based UTIO oil and a. ynlhetk ester-based gear oil (see Table 1).

The test' TIO oils have a kinematk vi cosi-ly between 9' mm2/s and ~] mm2/ . at ]OOC. Thisvi cosily offers ufflciem thickne s to promotegood gear protection and is tin suitable for 'thehydraulic sy tern. The synthetice ter G has a vis-co it)' two ISO grades higher than other test oilsand i mtable a a gear oil onJ:y.

The main difference between the vegetablebase rocks for R and S fonnulatioa lies in fa~tyacids contem (see Table 2). The high-oleic un-

0.35EE 0.3~

0.25I:co.~'Vi, 0.2co.E 0.15..uS, 0.1

t.4

E 1.2!.,~.2lm

O.BE,'"~

0.6''-'"0'\0 0.4'-'"II>~ 0.2

a Oleic Stearic Palmitic Linoleic 'linolenicfatty Acids

Hartzian Pressure, 3.17 .GPa; FrequencY,s 50Hz; A,mplitude,.1 ,000 11m; Speed, 0. I m/s;Temperature, SO' C; Duration, 120 min.

Figure 3-Antiwea,. propertief o/fatty acids.

(l) test ,pinion 141brace coupling m torque maasu ring coupling HOI shaft 1!2) lest gear 151locking pin (8) temperature sensor 1111shaft 2(3) slave gearbox (61load lever and weights (91tast gearbox 021 electric mater

Figure 4-Schematic section of.tlle FZG K,eartest rig.sliding motion was measured, The test rig config-uration and the test specimens are described inDIN 51 834 T2 (Ref. 5).

FIgure 2 shews the results of friction coeffi-cient measurement of the test oils. The mineral-based UTTO oil M shows the highest value ofaverage friction coefficient. The biodegradableoils exhibit less friction, especiallythe test oil G.Biodegradable UTIO oils with similar elemental,compositions of additives-R, S, and H-obtainalmost the same value for friction coefficient.

five different fatty acids contained in the veg-etable oils were tested OIl the SRV test device todemonstrate their antiwear properties (see Fig. 3).The oleic fatty acid proved to have the best anti-wear properties at the selected parameters,Antiwear properties and good oxidation stabilitymake the oleic fatty acid the most desired fattyacid in the vegetable lubricant oil formulation.

FZG test results. The FZG gear test rig iscommonly used to evaluate scuffing load capaci-ty, pitting resistance and slow-speed, high-loadwear resistance. Experiments are based on a fail-ure of a standard gear set, lubricated with thetestoil under specific test conditions, using the testrig illustrated in Figure 4 (Refs. 6-7).

The load-carrying capacity of lubricants wasinvestigated by using the standard FliG A/8.3/90test procedure. The test oil is subjected to a load ..increasing by stages, until the scuffing failure cri-terion bas been reached. Twenty mini meters oftooth scuffing indicate a test failure. The failureload stage is reported as a result (Ref. 6-7).

Investigations of the pitting resistance wereperformed on the FliG gear test rig in the standardpitting test CI8.3/90. After a two-hour run-in atload stage 6 (135..3 Nm), the test is run at loadstage 9 (302 Nm) until the failure criterion isrecorded. The number of pinion lead cycles whenthe critical damage of the tooth flanks occur isreported as a result (Ref 8).

UTIU oils are intended to Jubricatetransmis-sions and gearboxes of the tractors ..In such sys-tems, high temperatures, high loads and lowspeeds are very common conditions. Tile primarymode of failure observed witb the spiral bevelgearing is scuffing, while the planetary unitsencounter normal abrasive wear. There are a num-ber of methods to evaluate scuffing, but the pri-mary concern of this investigation is to simulatenormal. rubbing wear of the planetary gears. In theslow-speed, high-lead wear test, the C-type gearswere used to reduce the sliding velocity and con-sequently the probability of scuffing. The test pro-cedure is divided into two stages. The test gearsare weighed before and after each stage and theweight loss associated with wear is rec-orded as aresult which indicates the lubricant antiwear per-formance (Ref. 9-10).

The main FZG test conditions are summarizedin Table 3.

The results of the FZG tests are summarized inTable 4. The best results on the FZG test rig wereobtained with the synthetic ester-based oil G,which has a viscosity that's two ISO grades high-er than other oils.

The results of scuffing load capacity for UITOoils show better scuffing resistance for the formu-lated. high-oleic sunflower-based oil S, whichpassed the 11 th load stage while the other veg-etable-based formulation R and reference UITOoils passed the 10th load stage. Generally, UTTOoils exhibit a scuffing load stage between 9 and11; therefore all tested oils meet the e require-ments (Ref. 11).

The results of pitting investigations show supe-nor pitting resistance of the vegetable- and thesynthetic esters-based oils, compared with themineral-based UTTO eu The high-oleie sun-

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flower oil S showed very good pitting performanceamong the formulated UTIO oil .

The results of slow-speed, high-load wear inves-tigations indicate no significant difference in wearrates among the TIO oils. All te Ioils show lowwear rate in a low-speed. high-load fZO test

On the basis of the .fZG test results, we select-ed the formulated high-oleic sunflower-based for-mutation S for further investigations,

Uelicaw Gear 'TestHelical gear test rig. A helical gear lest rig was

used in order to demonstrate visco ity lability, anti-wear properties, oxidatienresi ranee and seaJ compat-ibility of the formulated high-oleic sunflower-basedUT1U oil labeled S in contmlledlaborarory condi-tions. Through periodic sampling of 'the lubricant andused oil analysis, the condition of thetestoil and partsofithe gearbox were detennined.

The helical gear test rig is schematically shownon Figure 5.. The AC drive motor with frequencyregulation runs a test gear-unit which is lubricatedwith the formulated high-oleic sumflower-basedtJTI10 oil S. For load simulation, as a brake. theDC generator and electric heaters are 1.1 ed, TheDm CK60 pinion and DIN CK45 gear, ea e hard-ened to 60-62 HRC and uot undercut, were usedduring the test. The e helical gears had face widthsof 30 mm, normal modules of 2.5 mm, and thedrive pinion had 31 teeth meshing in a 1:L5 rari o,The test rig was run continuously [2 hours per dayat a constant load of approximately 60' Nm oftorque. The oil temperature was maintained in therange of' 78-82C. A pair of helical gears wasrotated until the lubricant deteriorated.

Oxidation of lubricants is normally measuredby total acid number (TAN) and viscosity increase.New oils have an initial. TAN, therefore theincrease over the initial value measures oxidation.If the TAN exceeds 2.0 mg KOHIg over the origi-nal value, the oil shouldbe changed. (TIle unit "mgKOHIg" is the quantity in milligrams of potassiumhydroxide (KOB) needed to neutralize the acidconstituents in one gram of lubrication oil) Astrong indicator of oil degradation is also itsincrease in viscosity. Normally a 20% increa e inviscosityis a warning that the oil. is reaching theend of its useful life,

Oil cOlJditiolJ. The top line on 'the graph inFigure 6 represents kinematic viscosity oflhehigh-oleic sunflower-based UITO oil S, measured

~~_WearTable, 3:--fZG Test Conditions.

u~ ScuffingParameters, PittingStage I Stage II

I Test gears type A c1111.08 d stage " 9 HI.. 302 37.2.6 372.6Circumferential speed m/s 8.3 8.3 0.35 0.20Pinion rotational speed rpm 2,170 2,170 '93 53

1/.,-one stage until failureBunning time hour 20 30Sump temperature 'C 90. at start 90 121..... incrementally increased toad.

Oil Slow speed wearC/0.35-0.25/120

Iwe.ight loss in mgl

Table 4--HG Tes~Results.Sc uffing PittingA/B.3/90 C/B.3!90

. _ (FZG load staOfl'1 ~ ~ycles 01 pinianlR 10 13.96 11(16

111 26.75 1'()6 19/2211sG :>12 30.00" 1,(16

1'0 l'5.1fi61OS--------

HI 7.70 lOSM* pining, test. was stopped, but critical failure did not occur.1) Stage IIStage III.

electrometer test gearbox. electricbrak,e

generater

.FigllJ';eS-ScI,emalic d4JgrallJ oj the helical gear lest rig.

IL_ - - - - .........IF'"

1.- - .- .- .1

IKinematic viscosity /~ -: TAN r

~t- -- -. I

-l-1111"

IIii-

5

4

'CO--3 :I:,02OJ

2 .sz.s

0

;;; '50

~.. 40u

i 30.~..,eu .20'Su.z::>

'" 10E'"c::;;;:

0a 150 300 450 !600

Operating hours750 900

Figure fi...-..Trelld values for viscosity and TAN,by a table value until the sudden rise at 650 oper-ating hours, which indicates the oil deterioration.

,Gearbox condition. Oi1in the gearbox couJd bea very u eful condition monitoring media. If wecan separate the debris from the oil, we can iden-tify and. track an abnormal wear condition withouttearing down the equipment. Wear particles con-tained in the lubricating oil carry detailed and

at 40C. ArLer initial shear-down, the viscosity is important information about the condition of thetable until. 600 working, hours. when a slight oil-wetted cemponemsin the gearbox. If noe ces-

increase is observed. The bottom TAN line shows ive wear is observed, then this indicates that thethree distinct ection: initial increa e i .followed effective lubrication in the gearbox i maintained

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2000

1600...

1.- DL O-DS r--i-- I !,til 1200 r. I I0J li-DI

800 oj 0t 0400

.,,(')() ~

'f! u' v -v-v 9I (I

00 150 300 450 600 750 900

I Operating hours

Figur,e 7-Qltantitative Jerrography reading.

10,000 100

'. WPC WPCcr '" PLP J=jft ..- .... ~.......

I.., --

I-ot Running-in wear .....---- Normal wear --------. II I

80

60CL....JCL.

40

20

olOa o 750 900150 300 450 600Operating hours

Figl,re 8-Tr:elld values Jor WPC and PLP.during the operation.

The method used for the quantitative evalua-tion of the wear particle concentration was directreading (DR) ferrography. DR ferrography mag-netically separates wear particles from lubricantsand optically measures the relative concentrationof ferrous particles present in the oil sample. Theinstrument is able to detect particles in the lengthrange of 1-300 microns. The output of the DR fer-rography consists of two digital readings, a DL(density large) for large particles (> 5 um) and aDS (density small) for small particles (1-2 um)(Ref. 12).

Figure 7 shows the measured values for DLand OS for high-oleic sunflower-based oil S as afunction of operating time. These readings can beprocessed in several ways to allow easier identifi-cation of an abnormal wear mode. Two such waysare briefly described (Ref. 12):Total Wear Particle Concentration (WPC)

WPC=DL+DS (1)Percentage of Large Particles (PLP)

PLP= [(DL-DS)IWPC]*100 (2)Although the magnitude of the WPC is impor-

tant, the change from historical values is the iadi-

count. In normal operating conditions, a baselineof normal wear may be established and the aver-age of WPC values can be calculated.The average of Wear Particle Concentrationvalue (WPC",ea,,)

WPC",ean = l/n2;WPC* (3)where WPC* means that only normal wear dataare summed (outliers are excluded) .

The WPC value should not exceed the valueof an alarm limit-the critical wear particle con-centration that is based on the WPC"'.1l1Ivalue andstandard deviation of the normal samples (out-liers are excluded).The critical Wear Particle Concentration (WPCc,J

WPCcr = WPCmean + zo (4)where (J is a population's standard deviation.

The most informative method for DR resultsrepresentation is a plot of WPC and PLP in thesame graph, because an increase in both WPCand P LP is the best indication of an abnormalwear condition. Figure 8 shows (he calculatedvalues for WPC and PLP, which are plotted overtime. The WPC value shows an initial sharp risethrough a running-in process, during which thequantity of wear particles quickly increases andthen settles to a lower value after 350. operatinghours, when a normal wear period is beginning.The WPC and PLP values remain relatively con-stant in the normal running operation period,because the gearbox wear reaches a state of equi-librium in which the particle loss rate equals theparticle production rate.

An alarm limit for severe wear WPCcr can becalculated for the last six samples, because atleast three data in the normal wear period are nec-essary to determine WPCmean and a population'sstandard deviation cr before the WPCcr for thefirst point can be calculated. All WPC values arebeyond the alarm limit. therefore the gearboxoperates in the normal wear mode. The test wasended when the test oil started to deteriorate andbefore the gear failures occurred.

To avoid leakage problems. seals used in agearbox should be compatible with the test oil,Fluoroelastomer (Viton)was used as a seal mate-rial for the test, The seals were inspected after thetest and no change in the geometry was found.

DiscussionTwo formulated vegetable-based UTIO oils,

two synthetic esters, and a mineral UTIO oilwere investigated with respect to their gear pro-tection properties. The study has shown. that the

cator of machine wear condition. Quantitative fer- gear protection properties of the formulated veg-rography is a trending tool and not a particle etable-based oils are comparable with the corre-

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spending mineral-based oil, However. the FZGinvestigations show significantly better results

for pitting re i lance for the vegetable-ba ed oilsand synLl1eti.c e ters.

The vegetable-based oils and synthetic esters

exhibit very good lubricity in boundarylubrica-tion conditions. because the synthetic esters con-

Lain organic straight chain compounds with polarend groups=fauy acid (see Table 2). The polarnature of the biodegradable oils gives them agreater affinity for metal surfaces than nonpolarmineral oil . The need for anti wear additives isreduced. Therefore, with lower concentration of

the additive , both the vegetable- arid synthetic-ba ed oil how lower fri.cLion coefficients thanthe mineral test oil (see Figs. 1-2).

The FZG Lest results indicate that oil viscosity

has 3. strong influence on cuffing performanceand pitting resistance (Ref. 13). The best resultsare obtained with the ynthetic-ba ed gear oil,which has a vi cosity two ISO grades higher than

the UTTO te t oils. At the arne time. this syn-thetic ester has the lowe t concentration of addi-tive . The gear oils are generally of higher vi -cosity than hydraulic oils. but UITO oil is a mul-tipurpose lubricant that has 10 meet boththe gearprotection and hydraulic system requirements.

Vegetable- and synthetic-based oil haveexcellent viscosity propertie . Their viscosityindexes (VI) exceed 1.95. while the V] for miner-aI UITO cil equals ISO (see Table I),. The high-er VI allow- for the formation of the thicker

lubrication film and for better separation of the

contact surfaces at working temperatures (Ref.~4-15). The UTIO oils are of the arne ISOgrade vis co ity, but tests=-e pecially for pitting

resistance-show a great. differentiation in theresults. Besides the lubricant viscosity. the lubri-cant base stock: has a great influence on pittingresistance, while the additive type and concentra-tion have onty a minor influence. The fZjG pit-

ting test conditions corre pond to a Henzian con-tact point pre sure of 1.65 GPa. while contactpres 1IIfe at the SRV te ti 2.0 GPa. The pittingtest results elo ely follow the SRV inve tigations.Measured friction coefficient (Figure 2), the fattyacid content {Table 2). and antiwear propertie offatty acids (Figure 3) determine the pining per-formance ..The higher number ofcycles until fail-ure is thus a function ofthe lower sliding frictionat the point. of contact and. consequeruly, [ower

tangential stresses on the surface. which can effi-ciently prevent fatigue failure associated w.ith

SummaryThe vegetable-based lJITO oil formulations have

the advantages of having a green ouree of oil andlower cost than a biodegradable ynthetic UTfO oils.Agricultural equipment. is ideally uited to lise veg-etable-based oil because the tracto

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