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METAL’s Manufacturing Workforce Network

A DoW-funded partnership brings online courses and hands-on bootcamps to Purdue’s foundry lab, training that feeds gear production

Many students and job seekers are unfamiliar with the advanced technologies and career opportunities available in metal casting and forging. But thanks to the Metallurgical Engineering Trades Apprenticeship and Learning (METAL) program, led by the IACMI-The Composites Institute, that is changing. METAL is partnering with universities to showcase the rewarding careers these industries offer. Together, these institutions are hoping to revitalize American manufacturing by delivering responsive, scalable, and sustainable workforce development programs.

Automation for Every Shop Size

A new CNC-based application puts cost-effective robot part handling and articulation directly on the machine tool’s control screen, eliminating the need for a separate robot pendant

Perceive, Understand & Perform

AICA and Schaeffler demonstrate the role Physical AI can play in the manufacturing environment

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Technical Articles

Smart Alloying Eliminates Manufacturing Steps in Automotive Gears

20NiMo9-7 alloy achieves up to 48 percent higher fatigue strength than conventional carburizing steels in the as-carburized condition, eliminating the need for shot peening and grinding in automotive gear applications.

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Design Principles of Bevel Gears: Rationale for Zero Sum Profile Shifts and Generating Gear Choices

This article demonstrates why bevel gears are designed with a zero sum of profile shifts—showing that independent shifts merely replicate what a modified pressure angle already achieves—and explains the practical benefits of using conical generating gears for tooth profile crowning.

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Conjugate Bevel and Hypoid Gears

An excerpt from Gear Technology Solutions by Dr. Hermann J. Stadtfeld exploring the mathematics behind conjugate bevel and hypoid gears—from the fundamental laws of gearing and the conditions for perfect conjugacy to why real-world power transmissions require deliberate crowning rather than theoretically exact conjugate designs.

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Root Interference

This excerpt from Gear Technology Solutions explains how oversized cutter blade edge radii cause root interference in bevel gears, and how to select correct radii to avoid noise, flank damage, and tooth fracture.

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Design

Due to near-net shape production, additive-manufactured (AM) gears have a high potential to decrease costs and increase resource efficiency. The decreasing product life cycles as well as the increasing individualization of components demand high flexibility in manufacturing processes

Grinding

The world of bevel gear grinding is a complex topic. How do you determine which grinding and dressing parameters to select for a desired surface finish? What type of grinding wheel should be used? What type of dresser should be used? How do all these factors affect the gear noise and quality levels? These are some questions that will be addressed in this article.

Inspection

For precision measuring, skilled machinists, toolmakers, and inspectors must have accurate tools and gages, produced from quality materials, carefully manufactured, and rigidly inspected, to ensure lasting dependability. Gages have evolved throughout the years beginning with mechanical, then electronic models, and now convenient wireless electronic versions have come on the scene. Each type has an important place in today’s quality control and inspection processes.

Heat Treating

Gas carburizing has been around for a long time. One could argue that gas carburizing is the most common heat treating process. Heat treaters performing gas carburizing are often characterized by a dirty environment, hazy surroundings, and that “smell.” While the product quality may be acceptable, gas carburized parts do come with some challenges, like excessive intergranular oxidation (IGO) or intergranular attack (IGA), which is often ground off. Low-pressure carburizing (LPC) has proven to be a much cleaner and very capable alternative process. Most furnace companies have combined LPC with high pressure gas quenching, which moved carburizing from the dark back room to a relatively “clean room” environment. However, there is still a strong need for oil quenching, which is the common feature of the long used standard integral-quench (IQ) furnace.

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Videos

Forest City Gear Knows Robots!

Forest City Gear manufactures extremely high-precision gears made for the most advanced robotics, right in Roscoe, IL.  This family-owned team of gearheads specialize in high-precision gears engineered to handle the most demanding robotic applications—on Earth, and way beyond.

Industry News

Oak Ridge National Laboratory and Mazak have partnered for the development of a convergent metal additive manufacturing platform that unifies metal additive manufacturing and high-precision machining within production-relevant workflows. 

Product News

At IMTS 2026, chip and coolant handling experts Jorgensen Conveyor and Filtration Solutions will highlight their expanded FlexFiltration coolant management systems that extend coolant life, enhance part finishes, and reduce maintenance procedures and costs. In Booth #338009, Jorgensen will feature complete, fully automated systems that showcases compact modular designs with advanced customization for integration versatility in coolant filtration and monitoring.

Calendar

CTI Symposium Berlin 2026

Dec 8, 2026 - Dec 9, 2026

CTI Symposium Berlin offers active discussions on the latest technologies and strategies on automotive transmissions and HEV & EV drives for passenger cars and commercial vehicles. At CTI Symposium Berlin, more than 650 senior experts and decisionmakers from OEMs, Tier 1 suppliers, technology companies, and research institutions come together to discuss the latest developments in electrified drivetrains, hybrid technologies, energy systems, software integration, and future mobility strategies.

RPM Symposium 2026

Sep 22, 2026 - Sep 23, 2026

Furnaces North America (FNA) 2026

Oct 12, 2026 - Oct 14, 2026

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