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Archives May 2016

Archives

May 2016

FEATURES

Koepfer America, LLC

As the North American factory sales and technical support organization for high-end European gear machine and tool manufacturers, Koepfer America offers a line of solutions for almost every stage of the gear manufacturing process combined with excellent customer service.

In 1988, Koepfer America started as a supplier of Germany-based Koepfer gear hobbing machines. Today, Koepfer America is not only an independent factory sales and distribution company for Koepfer machines, but it is also a provider of full technical service and a complementary product line of gear hobbing machines, worm and thread milling machines, gear […]
Molly J. Rogers

Polish Grinding of Gears for Higher Transmission Efficiency

A new gear polish grinding process is presented to show that improved surface finishes increase the overall efficiency of transmissions, and the resulting higher bearing ratios reduce micropitting. A cost-efficient manufacturing method adapted for large-scale manufacture is also introduced.

The established continuous generating method was used as the base technology for the polish grinding process, which is distinct from the vibratory superfinishing used in many non-automotive applications. Continuous generating grinding is an established process for the hard finishing of gears. Based on a dressable grinding worm, this process has proven itself, both in terms […]
Walter Graf

State of the Art in Microstructure and Metallurgy Modeling

It’s important to understand the microstructure of forged parts in industries such as automotive and aerospace due to recent regulations, and simulation benefits are presented here to consider when working with rolled rings at different structure levels.

Anticipating the microstructure evolution during the manufacturing process has long been a major concern for specific industries such as aerospace. More recently, with the introduction of weight reduction regulations such as Corporate Average Fuel Economy (CAFE), the requirement to understand and control the microstructure of forged parts has permeated a number of other industries, more […]
Gear Solutions Magazine

The Benefits of Asymmetric Gears

A newly developed asymmetric gear tooth generating-grinding method combines maximum productivity with superior quality.

Gear wheels often rotate in only one  direction throughout their entire service lives. This applies particularly in the case of cars, commercial vehicles, ships, lifting gear, or generators. In the case of these gear drives, the tooth load on one flank is considerably higher than on the opposite one. This means that little or no […]
Andreas Mehr

DEPARTMENTS

Trend Talks: Training

Gear manufacturers and industry associations take on the responsibility of training the next generation of a qualified and skilled workforce.

Last month, I discussed the role that education plays in the gear manufacturing industry and provided examples of industry associations and companies that are on the forefront of driving the industry forward by developing an educated workforce. Similarly, training is crucial, and it goes hand-in-hand with educational opportunities both in the classroom and out on […]
Anna Claire Howard

Deep Nitriding for Gear Applications and Their Partial Treatments

Plasma/ion nitriding meets demanding gear applications by offering increased load capacity of gears and increased fatigue strength of components as well as less complicated masking treatments.

Stress conditions inside gear teeth are complex and require a careful examination by the designer before any specific surface treatment of the gears should be recommended [1]. As a result of those examinations, nitriding applications, specifically plasma/ion nitriding, for the surface engineering of gears have been growing steady in recent years because of the many […]
Dr. Edward Rolinski

Q&A with Kathy Saunders

Director of Marketing

Ellwood City Forge

How long have you been with Ellwood City Forge, and what is your role? I have been with Ellwood City Forge (ECF) for almost 30 years, primarily in sales and marketing positions. While I currently have some direct sales responsibilities with key customers, my main role is to promote ECF to customers in North America […]
Gear Solutions Magazine

Wind Turbine Gear Repair

Due to the large installed base of wind turbines, demand for gearbox repairs has risen steadily in recent years. Isotropic superfinishing is an ideal process for repairing damaged gear flanks and bearing surfaces found on used wind turbine gears.

Wind turbine gearbox durability has improved significantly over the past ten years. The days of early gearbox failure due to epidemic micropitting are largely in the past. Improved gear design and manufacturing have made these gearboxes much more reliable. However, wind turbine gears remain expensive and are manufactured by a limited number of gear producers. […]
Mark Michaud

Variables for Quality Design: The Design Process

The final outcome of the gear design effort and how well it delivers the defined objectives is directly linked to the rigor of the design process.

In the April Tooth Tips column, we covered specifications — the second major element that dictates the ultimate accuracy of gearing and how well it satisfies the customer. In this column, we continue the series by taking a look at the third major component for quality design: the design process. Gearing Design  Design, by its […]
Matt Mondek

NEWS

Nitriding Symposium Will Be Held on November 17-18 in Las Vegas

Nitrex Metal, along with United Process Controls, has recently announced that the 4th edition of Nitriding Symposium (NS4) will be held at the MGM Grand in Las Vegas, Nevada, on November 17-18, 2016. Nitriding Symposium is a triennial event that attracts metallurgists, engineers, plant supervisors, and manufacturing managers who deal with nitriding/nitrocarburizing in their manufacturing […]
June 7, 2016

UTC Aerospace Systems Expands Presence in Foley, Alabama

UTC Aerospace Systems recently announced that it is expanding its existing footprint in Foley, Alabama, by adding a new manufacturing and nacelle assembly facility that is estimated to bring 260 new jobs to Baldwin County. UTC Aerospace Systems, a unit of United Technologies Corp., is one of Alabama’s largest aerospace manufacturers as measured by number of employees. The new 80,000-square-foot […]
June 7, 2016

GTI Spindle’s North Carolina Facility Now Fully Operational

GTI Spindle Technology, headquartered in Manchester, New Hampshire, has recently announced that its newly opened North Carolina facility is fully operational. The state-of-the-art facility is staffed with industry-leading technicians who are capable of repairing and rebuilding the highest precision spindles including those made by Makino, Mazak, Kessler, Gamfior, Enshu, and OKK. "Now that we are […]
June 7, 2016

Itamco Receives DMDII Applied R&D Award for Smart Manufacturing Project

Itamco, a manufacturer of precision-machined components and specializing in gears, is part of a team that received an Applied Research and Development award from the Digital Manufacturing and Design Innovation Institute (DMDII). The award-winning project is titled “Standards-Based Platform for Enterprise Communication Enabling Optimal Production and Self-Awareness,” or SPEC-OPS. “We are excited to continue to […]
June 7, 2016

Oasis Alignment Services Standardizes Metrology Fleet with Hexagon Manufacturing Intelligence 6DoF Solutions

Hexagon Manufacturing Intelligence recently announced that Oasis Alignment Services, LLC (Rochester, New Hampshire) has standardized its large metrology fleet on Leica Absolute AT960 laser trackers and Leica T-Probes. Oasis is a leading provider of 3D metrology, optical alignment, and mechanical services with eight regional service centers throughout North America. The company serves a broad spectrum […]
June 7, 2016

AGMA Names Matthew Croson as New President

The American Gear Manufacturers Association (AGMA), a member and market-driven organization that conducts programs and provides services to the gear industry, its suppliers, and customers, has named Matthew E. Croson as its next president. Croson has more than two decades of leadership and communications experience in manufacturing trade associations and most recently served as president […]
May 27, 2016

Forest City Gear Adds Continuous Generating Grinding Capability for High-Volume Gear Production

Forest City Gear has expanded its high-volume gear production capabilities with the addition of a Reishauer RZ 160 gear grinding machine and high-speed load/unload automation. The system is part of a new 8,500-square-foot facility that is located in close proximity to Forest City Gear’s main plant and dedicated to the high-volume production of eight different […]
May 27, 2016

Parker Trutec Adds Fourth AFC-Holcroft UBQ Furnace

Parker Trutec, Inc. in Springfield, Ohio, recently added a fourth UBQ 36-48-36 universal batch integral quench furnace to an existing line. This furnace will be equipped for carburizing and be made CQI-9 compliant. The equipment was scheduled for installation in March 2016. Parker Trutec is a North American subsidiary of Nihon Parkerizing, a leading supplier […]
May 27, 2016

New Management Team at Bourn & Koch

Bourn & Koch, Inc. recently announced that Terry V. Derrico has been named president of the company. Joining him in senior management are Kerry Koch as CFO, Greg Champion as the vice president of sales and marketing, and Peter Mischler as the engineering manager. Derrico, who was most recently the president and CEO of United […]
May 27, 2016

Mahr Federal Names Stuart Manser as Director of Sales of Precision Gages

Mahr Federal has named Stuart Manser as the director of sales of precision gages for North America. According to CEO Tony Picone, Manser will be responsible for planning and directing the sales team for the precision gages product line, defining sales territory, and hiring sales staff. He will work in conjunction with the director of […]
May 27, 2016

SGS Tool Company Joins Commonwealth Center for Advanced Manufacturing

SGS Tool Company recently joined the Commonwealth Center for Advanced Manufacturing (CCAM). As a leading manufacturer of round solid carbide cutting tool technology for aerospace, metalworking, and automotive industries, SGS will participate in machining research activities at CCAM. “We are looking forward to collaborating with CCAM membership and the local manufacturing sector to provide improved […]
May 27, 2016

PRODUCT SHOWCASE: Gleason Introduces 500CB Cutter Build Inspection Machine

Gleason Corporation recently introduced its latest innovation, the 500CB Cutter Build inspection machine. The 500CB delivers more accurate and highly automated build, truing, and inspection of all types of stick-blade bevel gear cutters.   The 500CB features automated closed-loop blade positioning, creating a highly accurate and repeatable build quality. An accurately built cutter head is […]
May 27, 2016

PRODUCT SHOWCASE: Modular System for Direct Workpiece Clamping Offered from Schunk

The new Vero-S WDB clamping technology modular system transfers the efficiency levels of the Schunk Vero-S quick-change pallet system specifically to machine directly clamped workpieces. By using clamping pillars with a modular structure, freely molded parts and other workpieces can be clamped directly on the machine table without the need of additional equipment.  The modular […]
May 27, 2016

PRODUCT SHOWCASE: Thinnest Parting-Off and Deep-Grooving Tools Now Available

When material savings are a requirement due to machining expensive materials, large batch productions, or both, it is essential to use the thinnest insert width possible. CoroCut® QD-dedicated parting-off and deep-grooving tools are now available in smaller insert widths with internal high-pressure coolant to help customers achieve production efficiency. Considered a hidden machining cost, component […]
May 27, 2016

PRODUCT SHOWCASE: New SVF Series Grit Guard® Coolant Filter Is a Modular Solution for Abrasive Machining

Sunnen’s new SVF Series Grit Guard® coolant filter is a build-to-suit solution with progressively higher levels of filtration and chilling to meet process requirements in abrasive machining. Base Grit Guard models are available in 55- and 110-gallon capacities and are equipped with twin and quad Sunnen PF filter cartridges, with a total filtration capacity of […]
May 27, 2016

PRODUCT SHOWCASE: New Radius Internal Cylindrical Grinding Machines Added to Studer Line

United Grinding has added three new radius internal cylindrical grinding machines to its line of Studer internal cylindrical grinding machines. The S121, S131, and S141 replace STUDER’s CT700 and CT900 models and extend part production capabilities by offering more advanced technology, a new dressing concept, and a larger sized machine to handle a broader range […]
May 27, 2016

PRODUCT SHOWCASE: New Customized Enclosure for the Tigo SF Coordinate Measuring Machine

Hexagon Manufacturing Intelligence recently announced the release of a customized protective enclosure for the Tigo SF shop-floor coordinate measuring machine (CMM). The Tibox offers enhanced protection for systems operating in the most extreme workshop conditions, shielding against dust, airborne pollutants, oil particle suspension, and other manufacturing environment contaminants.  The Tibox is designed specifically to protect […]
May 27, 2016

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