Download the July 2014 Issue in PDF format

84 Pages·2014·20.04 MB·English

JUL
2014
CLEANER INSPECTION
SAME GEAR QUALITY
GEAR INDUSTRY-SPECIFIC
HEAT TREAT GUIDE
METROLOGY IN MOTION
TECHNICAL
ASK THE EXPERT:
GEARS — WHEN TO GO PLASTIC
HOW TOOL TOLERANCES MAY
INFLUENCE GEAR QUALITY
LOADED BEHAVIOR OF GEARS MADE OF
FIBER-REINFORCED PA6
INDUCTION HARDENING WITH PRE-HEAT
TO IMPROVE FATIGUE PERFORMANCE
ADDENDUM
ONE “SMALL STEP”
TOWARDS MARS?
www.geartechnology.com
THE JOURNAL OF GEAR MANUFACTURING
LLoonngg sspplliinnee aanndd
gear shaft hobbing
The Bourn & Koch 400H CNC horizontal hobbing up to 76” or longer can be processed by the extended
machine is a 7-axis CNC machine that can hob spur bed versions.
gears, helical gears, splines and threads on cylindrical All axes’ movements are supported by high-precision
blanks or shafts. ball screws and linear roller ways, resulting in very fast
Its powerful, direct drive work spindle and extremely setups and precise part machining. The through-hole,
stable, steel-polymer composite components make it work spindle drive allows clamping of shaft parts that
ideal for manufacturing large and heavy shaft parts up exceed the actual work area limitations.
to 406 mm in diameter and 6.4 module. Shaft lengths
Phone: [phone]
5200 Prairie Stone Pkwy. (cid:127) Ste. 100 (cid:127) Hoffman Estates (cid:127) IL 60192
2014-06_Star-SU_BK_Adv_2pages_us.indd 1 20.06.14 17:25
September 8-13, 2014
Long spline and
gear shaft hobbing
AA dduuaall ttooooll sseettuupp aalllloowwss ffoorr sseevveerraall ggeeaarriinnggss oonn oonnee
sshhaafftt oorr rroouugghh aanndd fifi nniisshh ccuuttttiinngg oonn oonnee ssppiinnddllee,, aanndd
iitt ccaann hhoobb wweett oorr ddrryy.. MMaacchhiinnee lleennggtthh eexxtteennssiioonnss aarree
also available. Learn more at our website or call us to
discuss your application.
Visit Star SU (booths N-6924 and W-2258) at IMTS
www.star-su.com
2014-06_Star-SU_BK_Adv_2pages_us.indd 2 20.06.14 17:25
contents
JUL
2014
22
42
features
technical
22 No Compromising on Quality at
Allison Transmission 46 Ask the Expert
Gleason gear inspection system Deciding When to Go Plastic
eliminates need for nital etching.
48 The Influence of Tool Tolerances on the Gear
Quality of a Gear Manufactured by an Indexable
26 Gear Industry Heat Treat
Insert Hob
Resource Guide
Tooth quality of test gear is analyzed using simulation
The only available gear industry-specific model in combination with Monte Carlo methods.
directory of heat treat service providers.
54 Loaded Behavior of Gears Made of Fiber-
42 R&P Metrology Measures Reinforced PA6
An original method for computing the loaded
Directly on the Production
mechanical behavior of fiber- reinforced polymer gears.
Machine
The growing need for compact, custom 62 Induction Hardening Process with Pre-Heating
and portable metrology solutions in for Improved Fatigue Performance of Gear
manufacturing is being addressed. Component
Flexibly controlling residual stress in root fillet and tooth
flank by pre-heating prior to induction hardening.
Vol. 31, No. 5 GEAR TECHNOLOGY, The Journal of Gear Manufacturing (ISSN 0743-6858) is published monthly, except in February, April, July and December by Randall Publications LLC, 1840 Jarvis Avenue, Elk Grove Vil-
lage, IL 60007, [phone]. Cover price $7.00 U.S. Periodical postage paid at Arlington Heights, IL, and at additional mailing office (USPS No. 749-290). Randall Publications makes every effort to ensure that the processes
described in GEAR TECHNOLOGY conform to sound engineering practice. Neither the authors nor the publisher can be held responsible for injuries sustained while following the procedures described. Postmaster: Send
address changes to GEAR TECHNOLOGY, The Journal of Gear Manufacturing, 1840 Jarvis Avenue, Elk Grove Village, IL, 60007. Contents copyrighted ©2014 by RANDALL PUBLICATIONS LLC. No part of this publication may
be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission in writing from the publisher.
Contents of ads are subject to Publisher’s approval. Canadian Agreement No. 40038760.
22 [www.geartechnology.com]
GEAR TECHNOLOGY | July 2014
our machines are
making history
December 2008 (date for illustrative purposes only)
An Illinois manufacturer produces critical gears
for Mars Rover “Curiosity” on their KAPP VUS 55P.
November 2011
Curiosity launches into space and on the sixth
of August, 2012 lands successfully on Mars.
December 2012
Curiosity’s mission is extended indefinitely.
December 9, 2013
Evidence reported from the Curiosity shows
Gale Crater contained an ancient freshwater lake
which could have been a hospitable environment for
microbial life.
Gears for the Curiosity Rover
February 19, 2014
were ground using the KAPP VUS 55P. In planning Curiosity’s route toward the slopes
of Mount Sharp, images piqued interest in the
striations on the ground formed by rows of rocks.
Gears good enough for NASA.
See photo at(www.photojournal.jpl.nasa.gov/catalog/PIA17947)
KAPP Technologies
2870 Wilderness Place Boulder, CO 80301
Phone: [phone] Fax: [phone] www.kapp-niles.com [email protected]
contents
Intelligence in Production.
Gear manufacturing technology innovations
from Liebherr.
Vol. 31, No. 5
During development of our innovations, we place particular
Visit us at:
departments emphasis on choosing an optimal solution for the respective
Chicago, Il. - USA
application. The result: Process stability and an outstanding
September 8 - 13, 2014
quality of manufactured components – with the highest North Hall,
06 GT Extras level of economy possible. Booth N-6930
Slone Gear; Unsung Heroes; IMTS 2014
08 Publisher’s Page
No Excuse is Good Enough
10 Product News
See technologies featured at IMTS 2014 and more
70 Industry News
Generating grinding machine
What’s news; who’s new; comings and goings LGG 180 / LGG 280
(cid:127) A single-table solution for gear grinding
76 Calendar of Events
of workpieces up to Ø 180 mm, or up
August 26–28: International Gear Conference 2014,
to Ø 280 mm, and workpiece lengths up
Lyon-Villeurbanne, France;
to 500 mm
September 8–10: Gear Failure Analysis Seminar, Big
(cid:127) Extremely fast load/unload times of 4
Sky Resort, Big Sky, Montana;
seconds, chip-to-chip, with a single-table
September 8–13: IMTS 2014, McCormick Place,
(cid:127) New Palletizing Cell LPC 3400
Chicago, Illinois.
77 Advertiser Index
How to reach every advertiser in this issue
78 Classifieds
Our products and services marketplace
80 Addendum
One “Small Step” Towards Mars?
JUL
2014
CLEANER INSPECTION Gear hobbing machine LCH 180 two Gear hobbing machine LC 180 Chamfer Cut
(cid:127) Multi-cut strategy with roll / press deburr-chamfering (cid:127) High chamfer quality with one-cut hobbing strategy
SAME GEAR QUALITY
(cid:127) Primary hobbing time is done in parallel to the load / unload, (cid:127) Primary hobbing time is done in parallel to chamfering
GEAR INDUSTRY-SPECIFIC and roll / press deburr-chamfering, between two cuts – on in a second machining position
HEAT TREAT GUIDE
METROLOGY IN MOTION two work-tables
TAECSGHKEN ATICHRAESL E—X WPEHRETN: TO GO PLASTIC
HINOFWLU TEONOCLE T OGLEEARRA QNUCAELSI TMYAY
LFOIBAEDRE-RDE IBNEFHOARVCIEODR POAF6 GEARS MADE OF Liebherr Gear Technology, Inc.
ITNOD IUMCPATOTRDIOOODNEVNWNEE DH AF“UAAMRSRTDDMIGESUAN EILMN PLGAE SRWRFTISOTEHR?P MP”AR EN-CHEEAT 1465 Woodland Drive
www.geartechnology.com Saline, Michigan 48176-1259
THE JOURNAL OF GEAR MANUFACTURING Photo by David Ropinski
Phone.: [phone]
E-mail: [email protected]
www.liebherr.com The Group
44 [www.geartechnology.com]
GEAR TECHNOLOGY | July 2014
2014-502_004 LVT_010_EMO_GB.indd 1 18.06.14 15:03
Intelligence in Production.
Gear manufacturing technology innovations
from Liebherr.
During development of our innovations, we place particular
Visit us at:
emphasis on choosing an optimal solution for the respective
Chicago, Il. - USA
application. The result: Process stability and an outstanding
September 8 - 13, 2014
quality of manufactured components – with the highest North Hall,
level of economy possible. Booth N-6930
Generating grinding machine
LGG 180 / LGG 280
(cid:127) A single-table solution for gear grinding
of workpieces up to Ø 180 mm, or up
to Ø 280 mm, and workpiece lengths up
to 500 mm
(cid:127) Extremely fast load/unload times of 4
seconds, chip-to-chip, with a single-table
(cid:127) New Palletizing Cell LPC 3400
Gear hobbing machine LCH 180 two Gear hobbing machine LC 180 Chamfer Cut
(cid:127) Multi-cut strategy with roll / press deburr-chamfering (cid:127) High chamfer quality with one-cut hobbing strategy
(cid:127) Primary hobbing time is done in parallel to the load / unload, (cid:127) Primary hobbing time is done in parallel to chamfering
and roll / press deburr-chamfering, between two cuts – on in a second machining position
two work-tables
Liebherr Gear Technology, Inc.
1465 Woodland Drive
Saline, Michigan 48176-1259
Phone.: [phone]
E-mail: [email protected]
www.liebherr.com The Group
2014-502_004 LVT_010_EMO_GB.indd 1 18.06.14 15:03
GT extras
THE GEAR INDUSTRY’S INFORMATION SOURCE
www.geartechnology.com
Our latest video featured on the Gear Technology
homepage comes courtesy of Slone Gear. This RANDALL PUBLICATIONS LLC
1840 JARVIS AVENUE
video shows a new way to measure tooth thickness
ELK GROVE VILLAGE, IL 60007
on internal parts using a span micrometer. The
gage is set to a master and then placed over sever- [phone]
al teeth. The Slone Gear software will calculate the FAX: [phone]
tooth thickness/dimension
under pins. For more infor- EDITORIAL
mation, visit www.youtube. Publisher & Editor-in-Chief
Michael Goldstein
com/watch?v=r3ARM7bLf_8.
[email protected]
Associate Publisher & Managing Editor
Randy Stott
[email protected]
Senior Editor
Jack McGuinn
[email protected]
Unsung Heroes Senior Editor
Gear Technology blogger Charles D. Schultz recently wrote about Matthew Jaster
[email protected]
the unsung go-to guys and gals that go unnoticed in most gear
shops. Read this post (The Invisibles: People Who Keep Shops Editorial Consultant
Paul R. Goldstein
Running) and others at www.geartechnology.com/blog/.
Technical Editors
William (Bill) Bradley
Robert Errichello
Octave Labath, P.E.
Joseph Mihelick
IMTS 2014
Charles D. Schultz, P.E.
Gear Technology will continue to feature the latest
Robert E. Smith
product and industry news items related to IMTS
DESIGN
2014 taking place September 8-13 at McCormick
Art Director
Place in Chicago. All the new technologies, products
David Ropinski
and can’t miss events will be available on our web- [email protected]
site as well as Twitter and LinkedIn.
ADVERTISING
Associate Publisher
& Advertising Sales Manager
Dave Friedman
E-Newsletter:
[email protected]
Sandvik Coromant, along with technology partners Star SU,
Materials Coordinator
Höfler, DMG Mori, Mazak, Okuma, Carl Zeiss, Zoller, Nikken CNC
Dorothy Fiandaca
Rotary Table and WFL, hosted a gear event in Schaumburg, [email protected]
Illinois. Read the recap in our recent E-Newsletter here:
CIRCULATION
www.geartechnology.com/newsletter/0614/sandvik.htm
Circulation Manager
Carol Tratar
[email protected]
Stay Connected
RANDALL STAFF
President
Follow us on Twitter
Michael Goldstein
twitter.com/#!/Gear_Technology
Accounting
Luann Harrold
Connect with us on LinkedIn
www.linkedin.com/groups/Gear-
Technology-Magazine-3893880
Subscribe Online
www.geartechnology.com/
subscribe.htm
6 [www.geartechnology.com]
GEAR TECHNOLOGY | July 2014
Haven’t heard
about Scudding ?
®
The answer is
this close...
:
Call 734-973-7800
and ask for Scott Knoy
GMTA brings the proven and patented Profilator technology of Scudding®
to the North American market, for special gear and spline applications.
With Scudding, quality meets speed in a new dimension of productivity,
FIVE TIMES faster than gear shaping. The surface of the workpiece is
formed through several small enveloping cuts providing a surface finish
and quality level far superior to hobbing, shaping, or broaching.
Scudding is a continuous cutting process that produces external and
internal gears/splines as well as spur and helical gearing, with no idle
strokes as you have in the shaping process.
Ring gears, sliding sleeves and annulus gearing, whether internal helical
shapes or internal spur, blind spline, plus synchronizer parts with block
tooth features, and synchronizer hubs are among the many applications
Profilator
for this revolutionary technology from GMTA.
Gear Machines, Featuring Our
Patented Scudding® Technology You want to know more, don’t you? Call Scott, he’s waiting to tell you
http://bit.ly/gmtascudding
all about Scudding.
For a preview, scan this QR code
See Us At
Now Representing
Arnold Laser Welding Machinery
and Rosink Parts Washers
German Machine Tools of America
Booth N-6670
4630 Freedom Drive | Ann Arbor, MI 48108 | www.gmtamerica.com | Email: [email protected]
GMTA—Ad4876-A—Gear Technology—IMTS—May 2014
publisher's page
Gear Up Your Quality Control
No Excuse is
Robot systems for quality control of surface treatment such as grinding and shot peening
Good Enough
by Barkhausen Noise and X-ray stress measurements.
RoboScan system
Might some of you may be tempted to skip IMTS
• automated inspection
this year? Business is just so-so. You can’t afford to be away Publisher & Editor-in-Chief
Michael Goldstein • all surfaces with one set-up
from the shop. It will be a waste of time because you don’t have
the budget for new machine tools or new technology anyway. stop there, because the non-gear equipment can often be just • safe, fast and easy measuring,
You’ve cut back on travel expenses. It’s your wife’s birthday. as important to your operations, especially with today’s multi- also on large and complicated parts
Maybe the last excuse is valid, but the others bear closer tasking machines. Or maybe you’ll need to visit the Quality
• instant feedback
examination. Assurance pavilion to learn how you can better streamline your
Most of you already know that IMTS often presents a unique inspection operations. The point is, every conceivable manufac- • quantitative results for production control
buying opportunity, because every machine tool manufacturer turing operation is covered at IMTS, and no matter what you • environmentally friendly
is there in the same place, and each of them is forced to com- consider your specialty, there may be opportunities to expand
pete for your attention and your business. This highly competi- your capabilities or increase your productivity that you haven’t
tive environment can result in good pricing if you’re in the mar- even considered.
ket to buy. If you look at our Product News section this issue, you’ll see a
But even if you’re not shopping for new technology, IMTS lot of examples of new technology that will be exhibited at IMTS.
has a lot to offer. It’s not just about buying machine tools, cut- We’re saving some of the best new products for our August IMTS
ting tools and automation. It’s about learning how the latest issue, but take a look beginning on page 10 to get an idea of the
processes and technologies can best be put to use. You can be breadth and depth of technologies that will be on display.
sure that the newest technology will be on display. You can also Then, stop making excuses and book your ticket for Chicago.
be sure that there will be plenty of experts on hand to help you IMTS only comes once every two years, and 100,000 visitors
understand how it can help you become more productive, effi- per show can't be wrong. No excuse is good enough. In fact,
cient or profitable. even if it is your wife’s birthday, bring her along. She’ll probably
These experts include the engineers who design the technol- enjoy Chicago, too.
ogy, the technicians who install it around the world, and the
sales people who have worked with companies like yours and
probably helped them solve many of the same problems you
face. You'll have the opportunity to develop and maintain rela-
tionships with the suppliers and potential suppliers who could
potentially have an impact on your operations some time down
the road. Even if now is not the right time to buy, you should go
to IMTS to learn what technology is available. Very often, when
the technology is right, it pays for itself anyway.
Don’t be fooled into thinking that you know everything
already. In my role as publisher of Gear Technology, it’s my job to
stay on top of manufacturing technology. Machine tool manufac-
For residual stress testing
turers constantly send us information about their latest advances.
I haven’t missed an IMTS in decades, and one thing that’s never by X-ray diffraction
changed is that there’s always something to learn. I’m confident Xstress Robot
that if you go, too, your experience will be the same. • reaches hard-to-reach areas
Gear manufacturers will have the opportunity to compare • handles complicated and large parts easily
the technologies of all the machine tool manufacturers special- • provides maximum flexibility and
izing in gear equipment by visiting the Gear Pavilion. But don’t easy positioning
• is fast and precise
www.stresstechgroup.com
8 [www.geartechnology.com]
GEAR TECHNOLOGY | July 2014