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Archives May 2014

Archives

May 2014

FEATURES

Company Profile: Richardson Manufacturing Company

Richardson Manufacturing Company is committed to meeting customer requirements and increasing customer satisfaction through continuous improvement.

Richardson Manufacturing Company (RMC) is not a stagnant company. “We’re constantly testing new technology and tooling,” says company president Bill Richardson. “For nearly 70 years, RMC specialized in high-precision CNC horizontal bore milling and vertical turning operations for large components. We pride ourselves on our ingenuity in workholding, cutting tool applications, and process development. Our […]
Tim Byrd

Improving Gearbox Reliability by Analyzing Axial Cracking on Bearings and Recommending a Solution

An analysis of the two types of early bearing damage observed with wind-turbine gearbox failures: micropitting and axial cracking.

Introduction As the growth of wind energy continues, the average size and capacity of wind turbine generators is also increasing. This size increase pushes designs and materials to new limits, potentially increasing the cost of operation; in particular the cost of repairs, downtime and unscheduled maintenance. Wind turbine gearboxes are typically designed and certified by […]
Scott Hyde

Cubitron II: Precision-Shaped Grain (PSG) Turns the Concept of Gear Grinding Upside Down

New abrasive grains developed by 3M are redefining the process of gear grinding.

To date, grinding, according to the German DIN Standard 8580, is “machining with geometrically undefined cutting edges” while other machining processes such as turning and milling are classified as processes with “geometrically defined cutting edges.” New abrasive grains, developed by 3M and called Precision-Shaped Grain, stands this definition on its head. For the first time, […]
Walter Graf

Topological Gear Grinding Methods

As gear grinding on modern CNC machines evolve, Kapp has introduced a modern method for the similar application on gear tools that could be used on internal teeth as well.

The word “topological” is often an over-used and misapplied adjective for design philosophies and manufacturing methods of gears. In the late 1970s, Maag used “Topological Modifications” with their SD series of zero degree dry grinding machines. The Maag zero degree method used single-point contact between the wheel and gear flanks during grinding and was capable […]
Bill Miller

Failure Analysis of H13 Gear Blank Forging Dies

Premature failure of forging dies costs the forging industry millions of dollars each year. Michigan Technical University and Walker Forge conducted research to reduce this problem.

Forging is defined as the process of working hot metal into a desired shape by impact or pressure1. The hot metal is formed into shape using dies that have the desired geometry machined onto their surfaces. Introduction Forging is defined as the process of working hot metal into a desired shape by impact or pressure1. […]
Gear Solutions Magazine

DEPARTMENTS

Closed Die Forging

Closed die (or impression die) forging have been a key metal working process for gears for many years.

Forging is the process of forming and shaping metals through the use of localized compressive forces.  Forgings are worked above their recrystallization temperature and are gradually shaped into the desired configuration through the skillful hammering, pressing, or rolling of the work piece.  Since both ferrous and nonferrous metals can be forged and raw material mills […]
Brent Blackowicz

Accuracy of Profile, Lead, and Spacing

Gear noise is affected by the accuracy of the profile, lead, and spacing. Accuracy, in this case, is the conformance to the specifications on the drawing.

Noise The primary cause of gear noise is the number of teeth in the gear and the contact ratio of the given set. These are design functions and we will not discuss them here. Control of the three basic elements (profile, lead, and spacing) also affects noise, and they are directly responsible for 2nd, 3rd, […]
Ron Green

An accurate comparison between LPC/HPGQ and endo atmosphere carburizing cell

Typically, LPC/HPGQ systems have evolved into individual batch carburizing chambers with continuous prewash, pre-oxidizing, and continuous tempers. Atmosphere carburizing cells retain a complete batch material handling arrangement, making an accurate comparison a little challenging. In the March and April columns, I presented operating cost for one 36” x 48” x 36” (900 x 1200 x […]
Jack Titus

Trend Talks: Tim Byrd

Today’s rapid-fire information superhighways mean the brightest ideas come through the fastest.

I never thought a career in technical writing would put me in contact with so many different cultures. Every week, I speak to people on the other side of the planet about the principles and practices that have brought them to success in the gear industry. Whether it’s a family business or not, they speak […]
Tim Byrd

Q&A with Steve Schilling

Managing Director, NUM Corporation

Tell me about your history with the NUM Corporation. I began my career as a controls engineer working for an OEM that built gear hobbers. I joined NUM in the early 1990s, first as an applications engineer developing special PLC/Motion and HMI software for a variety of different machine tools. For many years I was […]
Gear Solutions Magazine

NEWS

Methods Machine Tools to Host “Metal Storm 2014”

June 11–12 Methods Machine Tools, Inc. announced they are hosting Metal Storm 2014, a major open house event that will take place June 11-12, 2014 from 9:00 a.m.–5:00 p.m. each day at the company’s headquarters and corporate technology center at 71 Union Avenue in Sudbury, Massachusetts. Metal Storm 2014 will feature over 50 machines under […]
May 15, 2014

Gleason Gear Solutions Forum Attracts Visitors from 30 Countries

Gleason Corporation has announced the completion of the Gear Solutions Forum at its Gleason-Pfauter facility in Ludwigsburg Germany. Gleason hosted approximately 600 visitors from 30 countries over a three day period with a comprehensive display of the latest technologies in gear production and a series of leading experts from the gear industry and academia presenting […]
May 15, 2014

News of Note for German Machine Tools of America (GMTA)

• GMTA has announced the addition of Stefan Kloos as product manager. Stefan will handle the Pittler vertical turning lathes and WMZ centerdrive lathes. He will be based in Ann Arbor, Michigan, North American Headquarters for GMTA. • German Language and International Careers (LIC) students from Eastern Michigan University visited GMTA on March 12, 2013. […]
May 15, 2014

Seco to Showcase Advanced Milling Solutions at AmeriMold 2014

At AmeriMold 2014, June 11 and 12 in Novi, Mich., Seco Tools, LLC will showcase a wide variety of high-performance cutting tool solutions for high feed, square shoulder, face and copy milling applications in booth 716. Applications engineers will also be available to discuss productivity-boosting machining techniques for the mold making industry. High feed milling […]
May 15, 2014

Ipsen Builds Large Vertical Vacuum Furnace for Precision Metal Forming (PMF) Industries, Inc.

PMF Industries in Pennsylvania has selected Ipsen to manufacture a vertical MetalMaster vacuum heat treatment system. PMF will use this furnace to manufacture stainless steel, flow-formed products for the aerospace industry. This particular MetalMaster vacuum furnace has a 48” x 84” (1,219 mm x 2,134 mm) all-graphite hot zone with a 6,000-pound (2,722 kg) load […]
May 15, 2014

H-D Advanced Manufacturing Appoints Donald A. Brown as President and Chief Executive Officer of Overton Chicago Gear Corporation

H-D Advanced Manufacturing Company (H-D), a heavy duty industrial company focused on high-precision manufactured products used in motion control and other applications, has announced that Donald A. Brown has been appointed president and chief executive officer of its subsidiary, Overton Chicago Gear Corporation (OCG or the Company), a leading manufacturer and provider of large, custom, […]
May 15, 2014

PRODUCT SHOWCASE: New Solution for Worm-Gear Machining Triples Throughput, Eliminates Hobbing

Ingersoll has developed a new worm-machining process based on an inexpensive replaceable carbide-tipped milling tool that can cut cycle time by 3-to-1 and triple the tool service interval. Moreover, it does away with the hobbing machine and all the supply-chain issues associated with re-grindable HSS hobs. The setup that makes it all possible is a […]
May 15, 2014

PRODUCT SHOWCASE: Norton Abrasives’ Vitrium3 Promotes Excellent Grain Adhesion, Improved Product Versatility

Norton Abrasives, a brand of Saint-Gobain and a world leader in abrasives for over 125 years, has developed and launched Norton Vitrium3, engineered for maximum performance and cost savings in precision grinding. An entirely new abrasives platform, Norton Vitrium3 features a patent-pending bond technology developed by the Saint-Gobain Abrasives R&D team. This revolutionary bond features an exclusive […]
May 15, 2014

PRODUCT SHOWCASE: HDP 125 and HDO 125: New Intermediate Sizes for Parallel and Bevel Helical Gearboxes

The Bonfiglioli heavy-duty parallel and bevel helical gearboxes HDP and HDO are now more competitive thanks to the incoming new 125 size. HDP 125 and HDO 125 are available in 2, 3 and 4 stages, with a range of reduction ratios from 1:9 to 1:500. They feature an output torque above 49kNm. It improves both […]
May 15, 2014

PRODUCT SHOWCASE: Bodine 34B-WX Gearmotors Now Comply with Class I, Division 2 Standards for Use in Hazardous Locations

Bodine Electric Company now offers versions of their popular 34B-WX brushless DC (EC) gearmotors that are ETL listed and comply with National Electrical Code Class I, Division 2 safety standards. Designed to reduce the risk of accidental fires or explosions in hazardous locations, these gearmotors can be used safely in environments such as petroleum refineries, […]
May 15, 2014

PRODUCT SHOWCASE: Rohm Enhances Manual Lathe Chucks

The ZG and ZS manual lathe chucks from Röhm Products of America feature enhanced designs that include control edges for adjustability, safety adapters to regulate force and spray water rims that protect machine tool spindles. The control edges on the chuck bodies allow for fast and simple on-machine scroll adjustments. The new safety adapters on […]
May 15, 2014

Gleason and SMT Partnership Provides Engineers with Complete Design System for Bevel and Hypoid Gears

Gleason Corporation (Rochester, New York) and Smart Manufacturing Technology Ltd. (SMT) (Nottingham, UK), have announced the release of the first phase of their strategic global partnership. New versions of SMT’s premier full-system transmission design and analysis software (MASTA) and Gleason’s industry-leading software for bevel and hypoid gear design and manufacture (CAGE™) are now available with […]
April 14, 2014

DMG Mori Hosts

DMG Mori USA hosted The Association for Manufacturing Excellence “AME Values Veterans” Symposium on March 14th at its U.S. Headquarters in Hoffman Estates, Ill. The one-day event offered training, coaching, and advocacy for organizations that pledged to hire and retain veterans, transitioning guardsmen, and reservists. The program focused on manufacturing industry best practices for meeting […]
April 14, 2014

Mitsubishi Heavy Industries America Welcomes Ross Wegryn-Jones to Their Sales Team

Mitsubishi Heavy Industries–Machine Tool Division is pleased to announce the employment of Ross Wegryn-Jones as regional sales manager for gear machines. Ross has vast experience in the gear industry, from gear, spline, and shaft products to print, gear grinding, measuring machine tools, and workholding.  Ross has over 24 years experience in the machine tool and […]
April 14, 2014

EMAG Apprentice Program with Two Michigan Colleges

EMAG L.L.C. has an ongoing interest in providing job opportunities for highly skilled, specialized machine tool technicians. To encourage continuing growth in Michigan’s mechatronics manufacturing industry and ensure an advanced workforce to close the sector’s skills gap, EMAG has launched an apprentice training program, together with the Michigan Economic Development Corporation, Oakland Community College and […]
April 14, 2014

Jenoptik Industrial Metrology Introduces the Better Parts Challenge

Jenoptik Industrial Metrology has announced the launch of its special 2014 event: The Better Parts Challenge. The company will be inviting U.S.-based manufacturers to bring their part quality challenges to its experts.  These demonstrations will take place at road shows across the U.S., showing how Jenoptik measuring devices and software can make better quality parts […]
April 14, 2014

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