Archives December 2016


December 2016



As an innovative leader in production technology, Felsomat provides highly efficient and flexible systems for the transmission and engine manufacturing industries.

Based in Koenigsbach Stein, Germany, Felsomat GmbH was founded in 1981 by Helmut F. Jaeger — initially manufacturing small pick-and-place devices and simple automations systems. In 1990, Felsomat became a trendsetter in the machine tool industry with its introduction of the FZ 250 compact cell. This automation system revolutionized the way in which small gears […]
Molly J. Rogers

Accelerated Testing and Temperature Calculation of Plastic Gears

Comparing different material combinations and testing conditions, results are presented from an accelerated testing procedure for polymer gears to provide a more accurate calculation of gear temperatures.

Plastic gears have been in use since the 1950s, and their popularity has increased significantly in the last few years. The mass production of plastic gears using injection moulding and newly developed plastic materials have additionally increased the application of plastic gears in automotive and medical areas. The primary advantages of plastic gears are low […]
Joze Tavcar, Dr. Aljaz Pogacnik

Application of Advanced Mesh Analysis To Eliminate Pinion Failures

A case study demonstrates the benefits of advanced mesh analysis, including design and application of optimized microgeometry through precision tooth form grinding. Recommendations can be applied at the design phase to optimize gearing performance or, reactively, to identify root cause of failures.

Through a case study involving pinion failures on plastic extruder drives, this paper covers failure analysis, gear rating review, application of advanced mesh analysis to define component deflections causing loaded mesh misalignment, and reduced tooth contact/high stress concentration resulting in tooth macropitting. The paper demonstrates the capability and benefits of advanced mesh analysis, including design […]
Terry Klaves

Pitch Factor Analysis for Symmetric and Asymmetric Tooth Gears

Pitch factor analysis is an analytical tool that can be used for comparison of different gear geometry solutions by exploring the characteristics of involute gear mesh parameters that define gear drive performance.

In comparison with traditional gear design based on pre-selected, typically standard generating rack parameters and its addendum modification also known as the X-shift, the alternative Direct Gear Design® method [1, 2] provides certain advantages for custom high-performance gear drives that include increased load capacity, efficiency, and lifetime and reduced size, weight, noise, vibrations, and cost. […]
Dr. Alexander Kapelevich


Comparing Surface Roughness Parameters

Measurements such as Ra, Rz, and Rsk may not effectively evaluate isotropically superfinished surfaces.

Effective gear design must account for a range of potential failure modes. As discussed in previous Materials Matter columns, gear failure modes can be fatigue-based and progressive (such as micropitting) or sudden (such as scuffing). Surface roughness is an important design factor in predicting and avoiding gear failure. Therefore, accurate classification of surface roughness is […]
Matt Bell

Requirements for Gear Design

The following steps help ensure a successful gearbox is designed and specified, and all of the customer’s desired attributes and design inputs are met.

A gearbox design program includes technical and non-technical requirements, including legal and regulatory as well as commercial considerations. The process starts with a description and full understanding of the type of gear or gearbox required and the nature of the application: what type of machine will it be used in, where and how will it […]
Rick Miller

Trend Talks: Virtual Reality

It’s no holodeck, but virtual reality in heavy industry is becoming a reality.

Science fiction has done a lot to inspire and influence aspects of everyday life. Engineers and industrialists look to what fiction writers have thought up out of thin air and have tried to make them reality. Lasers, smartphones, GPS tracking, and more got their start in the pages of sci-fi novels and movie scripts. Industry […]
Kenneth Carter

Q&A with Thomas J. (Buzz) Maiuri

Each issue, Gear Solutions talks with company leaders so they can share their experiences in the industry.

Tell me a little about yourself and your career with The Gleason Works. A week after I graduated from high school in Rochester, New York, I started my career at The Gleason Works, entering their Associate in Engineering Training program in 1966. It was a four-year apprenticeship where the trainees worked six- to eight-week blocks […]
Gear Solutions Magazine

Thermochemical Surface Technologies Applicable to Gears

Comparing wear resistance of nitrided and carburized cases formed on the same steel can help designers choose which method to use.

Hardening of the gear surfaces has a profound effect on their performance. Reduction in friction, enhancing rolling contact fatigue resistance, and other tribological properties of the surface can be utilized by application of various surface techniques available to the manufacturing industry. For surfaces hardened by a diffusion process, what really matters is the depth of […]
Dr. Edward Rolinski


Klingelnberg Adopts Industry 4.0 Through Compatibility Among Systems

Unlike a number of companies in other industries, machine manufacturer Klingelnberg is banking on compatibility, not a self-contained solution, in its quest to adopt Industry 4.0. According to the company, it’s not about networking in-house machinery alone. It’s about integrating a plethora of systems and software into a cyber-physical production system. And it’s an approach […]
January 9, 2017

ITAMCO Attends White House Event

ITAMCO, a manufacturer of precision-machined components, specializing in gears, attended an event at the White House hosted by the National Economic Council on December 21, 2016. The function was held in recognition of the progress made by ITAMCO and other U.S. manufacturers in the Manufacturing USA program. Daniel Neidig, vice president, and Joel Neidig, business […]
January 9, 2017

Emuge and Mastercam Establish Partnership

Emuge Corp., a manufacturer of high-performance taps, drills, end mills, and other rotary tools, announced it has established a partnership with CNC Software, Inc., developers of the manufacturing industry’s well-known Mastercam® CAD/CAM software. Emuge and Mastercam are planning training and seminar events for 2017. Both companies will share technical data and best practices on machining […]
January 9, 2017

Index Develops New G200 Turn-Mill Center

Index has developed a new generation of its turn-mill center G200, a compact machine offering higher performance in the same footprint as the earlier generation. The redesign resulted in an increase of the maximum turning length to 660 mm, a higher performance milling spindle, and expanded live tool complement as well as the XPanel with […]
January 9, 2017

Samputensili Appoints Deniz Sari as New Gear Technology Manager

Samputensili announced the recent appointment of Dr. Ing. Deniz Sari to the newly created position of gear technology manager for Samputensili and its joint venture Star SU. According to the company, Deniz is a talented leader and industry expert who brings significant experience, knowledge, and passion for gears to the business. In his new role […]
January 3, 2017

Gear Motions Relaunches Pro-Gear Division and Offers Gear Grind Only Service

The Pro-Gear division of Gear Motions Inc. is being relaunched as a gear grind only division. Pro-Gear will focus exclusively on providing high-precision, high-quality gear grinding services with quick turnaround time and low tooling cost. This service will appeal to gear manufacturers that need additional capacity and machine shops that require external gear grinding services. […]
December 15, 2016

Klingelnberg Debuts New Cylindrical Gear Machining Technology at In-House Event

At a two-day in-house event on November 9-10 at the Ettlingen Oberweier (Germany) Works, gear industry experts from Europe, Asia, and the United States had the opportunity to take a close look at the Höfler cylindrical gear machines of the system provider Klingelnberg. The company’s latest innovation — direct networking of a Höfler cylindrical gear […]
December 15, 2016

Koepfer America Teams with TecnoMacchine To Offer CNC Deburring and Chamfering Solutions

Koepfer America has expanded its robust line of gear manufacturing solutions by partnering with TecnoMacchine of San Salvo, Italy. TecnoMacchine manufactures CNC deburring and chamfering machines, and the company offers several options for flexible automation. Consequently, North American gear manufacturers will benefit from TecnoMacchine’s fit in Koepfer America’s line of high-tech machine tools. Multiple standard […]
December 15, 2016

Wickert’s Hardening System Receives Prestigious 2016 Innovation Award

Wickert Hydraulic Presses of Landau, Germany — a global manufacturer of fixture hardening systems for heat treated and high-tolerance parts that require forming and hardening — was recently honored by the Ministry of Economics (RLP, Germany) with an Innovation Award of 2016. Left: Dr. Volker Wissing, Minister of Economics, center: Stefan Herzinger, managing director, Wickert, […]
December 15, 2016

Mahr Federal Inc. Announces Expansion Plans in the Southeast

Mahr Federal Inc. has recently announced plans to expand its direct sales coverage for metrology system products in the Southeast. Effective immediately, Mahr metrology system products will be sold directly by the Mahr Federal Inc. sales team in Alabama, Florida, Georgia, Mississippi, North Carolina, South Carolina, and Tennessee. “We presently are searching for additional sales […]
December 15, 2016

PRODUCT SHOWCASE: Gleason Introduces 300GMSL Multi-Sensor Inspection Machine

Gleason Corporation recently introduced its latest innovation in gear inspection technology with the 300GMSL Multi-Sensor Inspection Machine, providing the capabilities of four instruments on one platform. Designed for manufacturers of automotive, aircraft, and other like-sized gears, the 300GMSL offers a single, compact, reliable, and easy-to-operate inspection solution to apply the most desirable gear measurement and […]
December 15, 2016

PRODUCT SHOWCASE: Toyoda Unveils First-Ever Synchronous Control of Gear Machining with Skiving Technology

Toyoda’s new GS300H5 Gear Skiving Center is the first in the world to equip a skiving function to a general-purpose horizontal-type machining center, through which mass production of gear parts is achieved. CNC controls and a high-speed rotary table were developed specifically to achieve high-speed, multifunctional machining as a compact and lightweight product and simple […]
December 15, 2016

PRODUCT SHOWCASE: Liebherr Introduces Compact, Flexible Gear Shaping Machine

Liebherr-Verzahntechnik GmbH has expanded its machine portfolio for small workpieces with the small-footprint (Platform 1) LS 180 F shaping machine equipped with an electronically operated, movable cutter head slide. The machine can shape smaller gears in different axial positions with only short setup times. The machine is suitable for job shops, especially with aerospace work. […]
December 15, 2016

PRODUCT SHOWCASE: KISSsoft Release Determines Misalignment of Bevel Gears

The relative position of the pinion and the ring gear is critical in determining the wear patterns of bevel gears. To determine the bevel gear misalignment, the displacements of the shafts can be directly determined in KISSsoft Release 03/2016 by linking the shaft files to the bevel contact analysis. The VHJ displacement values are defined […]
December 15, 2016

PRODUCT SHOWCASE: Methods Introduces Innovative, Compact KIWA Horizontal Machining Center

Methods Machine Tools, Inc., a leading supplier of high-performance machine tools and automation solutions, recently announced the addition of the KIWA-Japan Triple H40 horizontal machining center with a column traverse structure to its KIWA line. One of the most unique design features of the Triple H40 is its ability to support flexible mounting of various […]
December 15, 2016

PRODUCT SHOWCASE: AIMS Pairs Renishaw 5-Axis Scanning Technology with the Industry’s First Linear-Motor Driven CMM

When it comes to coordinating measuring machines, manufacturers want less downtime and lower cost of ownership. In response to customer feedback, OEM AIMS Metrology has designed and introduced the industry’s first linear motor-driven CMM with 5-axis measurement capabilities. AIMS’ Revolution LM series combines a robust frame with Renishaw’s Revo 5-axis scanning system to provide submicron […]
December 15, 2016

PRODUCT SHOWCASE: Gear Break-In Lubricity And Rust Protection Achieved With Tru Temp Black Oxide

Gear component manufacturers can easily achieve break-in lubricity, robust corrosion protection, and galling resistance on critical components. Birchwood Technologies’ Tru Temp® low temp black oxide process meets demanding finishing requirements while creating a non-dimensional finish, maintaining the same material hardness and load-bearing properties. The Tru Temp blackening line operates at 200 degrees and forms a […]
December 15, 2016

PRODUCT SHOWCASE: Ipsen’s MetalMaster Furnaces Shipped to Customers Worldwide

Ipsen has recently shipped five MetalMaster® vacuum furnaces to companies in locations around the world: Washington, South Carolina, Mexico, and China. Comprised of both horizontal- and vertical-loading systems, these shipments will be used to process parts for the commercial heat treating and aerospace industries — a market where Ipsen and its equipment have a strong […]
December 15, 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 Felsomat FRC 600 high-speed load/unload automation. The system is part of a new 8,500-square-foot facility located in close proximity to Forest City Gear’s main plant and dedicated to the high-volume production of eight […]
December 13, 2016

Des-Case Launches Redesigned Product That Improves Contamination Monitoring

Des-Case Corporation recently launched an entirely redesigned oil sight glass (OSG) that pushes the boundaries of what oil sight glasses can do. The new sight glass — a clear cylinder that can be installed in the drain port of the oil reservoir of pumps, gearboxes, bearing housings, and other pieces of equipment — can play […]
December 7, 2016

Koepfer America Announces 2017 Gear School Dates

The seminar “Fundamentals of Parallel Axis Gear Manufacturing” on May 23–25, 2017, is designed for entry-level gear manufacturing personnel. Attendees include manufacturing management, industrial engineers, supervisors, set-up personnel, operators, and quality control. It’s an intensive three-day program with a limited class size of 30. Over 1,300 people have attended Koepfer America’s “Gear School.” The seminar […]
December 7, 2016

Mazak to Open New Technical Center in Texas

Mazak announced the opening of a second facility in Texas. Joining the company’s Southwest Technology Center in Houston, the new Mazak Dallas Technical Center will serve the Northern Texas region. To celebrate the expansion, Mazak is hosting an Open House on February 1, 2017, which will feature machine demonstrations, special guest speakers, and tours. The […]
December 7, 2016