Thursday, April 22, 2021
Archives September 2014


September 2014


Robust Gear

Robust Gear has been manufacturing high quality custom precision gears for over 25 years, and they aren’t slowing down anytime soon.

Robust Gear was incorporated in August 1985, by Tarsem (Sem) Tak in the town of Oakville, Ontario. Tarsem‘s dream was to create a niche in the custom gear market that would be fulfilled and serviced by his company. By the time of his death in December 2012, Tarsem had built up a solid reputation of […]
Tim Byrd

Gear Resonance Analysis and Experimental Verification Using Rapid Prototyped Gears

Tests to reduce risk are used to build confidence in the design and analysis techniques before the final product reaches an aircraft.

Weight reduction is of great importance in the design of gearing for aerospace applications. Natural resonance responses of the gear head and shaft change in frequency and amplitude as weight is reduced for aerospace gears. Care should be taken to understand the gear resonance modes and compare the modes with operating speeds. Modes should be […]
Jeffrey D. Hayes, Scott R. Davidson

Upgrading and Testing a 72,000 H.P. Gearbox

Transmitting 54 megawatts, or 72,000 horsepower, through one gear mesh at a pitch-line velocity of 29,000 feet per minute is not child’s play.

Another Day at the Gear Hospital Over the past 40 years, we have had many gearboxes come to our door that have had chronic, operational issues in need of remedial treatment. Sometimes, the fix is straightforward, and sometimes it’s pretty complex. Design Model This last year, The Gear Works became involved in a gearbox repair […]
Roland Ramburg

UNIMILL: Prototype and Small Batch Bevel Gear Manufacturing

The UNIMILL method produces bevel gear geometries identical to those produced by face milling cutters.

Manufacturing of spiral bevel and hypoid gears can be conducted in several ways. The following methods are commonly known: • Face hobbing with a circular face cutter, which rotates while the work rotates in the opposite direction (continuous indexing). • Face hobbing with tapered hob (peripheral cutter), which rotates while the work rotates as well […]
Dr. Hermann J. Stadtfeld

A New Innovation in Spline Rolling Rack Tooling

The R/C Rack System is the first major innovation in spline rack tooling since the inception of the process 60 years ago.

The spline rolling process was invented by the Michigan Tool Company in 1954. The tools used for the process, commonly referred to as spline racks, are solid pieces of toothed tool steel designed in such a manner as to cold form the appropriate number of external involute spline teeth on a work piece, typically a […]
Mike Callesen


Manufacturing DIN 5481 Type Spline Serrations

DIN 5481 type spline serrations can be manufactured by milling cutter, hob, broach, and rolling.

This month, we will focus on calculating and sizing DIN 5481 type spline serrations for any application. The latest document is a 2009 update to the original 1956 standard. However, the document is not available in the U.S. due to publishing restrictions. As far as I know, it is only printed in German. Nevertheless, the […]
Fred Eberle

Tool Coatings and Dry Cutting

The high cost of dry cutting is offset by the higher cutting speeds it offers.

There has been a movement in recent years to dispense with the use of coolants in gear cutting. This has been normal practice in cutting cast iron but has been unachievable in the cutting of steel with “traditional” high speed steels. The advantages of dry cutting include: • coolant cost • cleaner environment • no […]
Ron Green

Metallurgical and heat-treat forensics play important part in determining how and why parts fail

Automobiles and airplanes have been in the news recently — GM cars for ignition recall issues and airplanes because of crashes due to weather, missiles, and undetermined reasons. No matter the case, metallurgical and heat treat forensics play an important role in determining what and how things happen. Cars and airplanes contain steel, cast and […]
Jack Titus

Trend Talks: Tim Byrd

Gear Solutions speaks with a handful of industry experts about how precision technology has shaped their products and clientele.

With dazzlingly precise multi-axis machines, better technology is leading to better tools, design ideas, and better gears. It’s no surprise:  metallurgists have been thinking 20 years ahead since, well, forever. When they invent something that takes gear manufacturing to the next level, it opens up a market for more improvement. But I’ve been wondering lately […]
Tim Byrd

Q&A with Bruce Cox

Bruce Cox Engineering Corporation

You provide assessments to ISO/IEC 17025 for calibration laboratories. How has business been? I do assessments now, that’s the main thing, for the National Voluntary Laboratory Accreditation Program (NVLAP), part of the National Institute of Standards and Technology (NIST). Things are going good. I’m getting busy, going through the process of looking at different companies’ […]
Gear Solutions Magazine


Manufacturing Technology Orders Rise in June

June U.S. manufacturing technology orders totaled $405.73 million, according to AMT   (Association for Manufacturing Technology). This total, as reported by companies participating in the USMTO program, was up 12.6% from May, but down 2.1% when compared with the total of $414.26 million reported for June 2013. With a year-to-date total of $2,349.38 million, 2014 is […]
September 21, 2014

Take a Virtual Field Trip with Sandvik at IMTS

Developed by educators and manufacturing industry experts, “Technology Applied” is a virtual field trip that connects academic courses to development of important products. The interactive web broadcast, from IMTS September 8th-13th in Chicago, will show students why math and science matters, and how the courses they take today can be applied in productive and rewarding […]
September 15, 2014

AMT’s Emerging Technology Center to Feature 3-D-Printed Electric Car at IMTS

AMT’s Emerging Technology Center (ETC) is on track to “wow” IMTS 2014 visitors. “At IMTS 2004, we created the Emerging Technology Center to present manufacturing ‘technologies of the future’ from leading universities and government research labs,” said Peter Eelman, vice president — exhibitions and communications, AMT. “This feature returned IMTS to its roots as a […]
September 15, 2014

Hypertherm Offering Free Workshops on Advanced Cutting Topics

Hypertherm, a U.S.-based manufacturer of plasma, laser, and waterjet cutting systems, is adding three new cities — Tulsa, Atlanta, and Houston — to its 2014 live training tour on advanced cutting topics. The workshops, valued at $250, are offered at no charge to people who cut metal and other industrial materials. On September 16, Tulsa […]
September 15, 2014

Meet the Next Generation of Universal Robots at IMTS

Visitors to Universal Robots’ booth E-4841 at IMTS 2014 get the opportunity to program a robot with safety features that adjust to the context it operates within. Esben Østergaard, CTO of Universal Robots, explains that the patented new safety concept is a logical development of the Danish robot manufacturer’s collaborative robot arms. “With the integration […]
September 15, 2014

PRODUCT SHOWCASE: Advanced CNC Systems from NUM Extend Competitive Edge

Advanced CNC systems from NUM are helping U.S. machine tool manufacturer Bourn & Koch, Inc. to extend its competitive edge in the market by using state-of-the art machine control software. Following a highly successful project to migrate control of powerful 7-axis horizontal gear hobbers to NUM’s Flexium CNC platform, the company is now standardizing on […]
September 15, 2014

PRODUCT SHOWCASE: Bourn & Koch Add to Gear Shaper Offering

The Bourn & Koch Fellows HS2550-600 CNC Hydrostroke™ Gear Shaper is a true bridge type 100” gear shaper with a 0” center distance reach even when the outside diameter of the gear is 100”.  A 24” (600 mm) stroke length allows long face width capability with a CNC controlled spindle for programming stroke positioning, stroke […]
September 15, 2014

PRODUCT SHOWCASE: GCH Tool Group Announces Release of Centerless Grinder Guide

GCH Tool Group, the world’s largest supplier of spare parts, components and assemblies for centerless, ID, OD, double disc and surface grinders, is pleased to announce the release of its centerless grinder guide. This 16-page, full-color guide presents an “at-a-glance” snapshot of the company’s main offerings. “Our new guide shows the depth of our inventory,” […]
September 15, 2014

Manufacturing Technology Orders Rise in June

June U.S. manufacturing technology orders totaled $405.73 million, according to AMT   (Association for Manufacturing Technology). This total, as reported by companies participating in the USMTO program, was up 12.6% from May, but down 2.1% when compared with the total of $414.26 million reported for June 2013. With a year-to-date total of $2,349.38 million, 2014 is […]
September 15, 2014

Polygon Solutions Expands Tooling Product Line

Polygon Solution Inc.’s new ‘Made in USA’ broach is a rotary broach with multiple text letters allowing machinists to stamp or mark their part in a lathe or milling machine without removing the part from the machine. The rotary broaching system is usually used for making hexagon, square or gear shape holes in precision machined […]
August 13, 2014

JUNKER Group Continues to Expand Product Diversity

JUNKER, ZEMA, and LTA exhibit their latest machines and equipment under the JUNKER Group umbrella during the IMTS in Chicago from September 8 – 13. The Brazilian grinding machine manufacturer ZEMA partners since May on a global basis with the German manufacturer of precision grinding machines. As an introduction of the partnership, ZEMA is presenting the […]
August 13, 2014

SW North America, Inc. Opens Canton Technical Center

SW North America, Inc., a leading manufacturer of precision metalworking production machines, has opened its new North American sales and technical center to better serve and support its customers. The new Canton Technical Center is located at 40615 Koppernick Road, Canton, Mich. 48187-4280.  Located in the Detroit metropolitan area, the new office allows SW North […]
August 13, 2014

New Standards For Industrial Maintenance and Mechatronics Technicians: Call for Input

The National Institute for Metalworking Skills (NIMS), the precision manufacturing industry’s premier standards and workforce certification body, is pleased to present the first draft of National Skill Standards to support the development of a world-class industrial maintenance and mechatronics workforce. The standards are the foundation of quality training and industry credentials that give individuals industry-certified […]
August 13, 2014