Rebuilt and redesigned, Fanuc announces the release of Roboguide Version 10, the latest and most advanced iteration of its offline robot programming and simulation software. Designed to enhance efficiency, visualization, and user experience, Roboguide continues to be the go-to solution for companies seeking to streamline automation design and implementation.
Precision regrinding leaves no room for error. At Fraisa, direct data transfer between Zoller measurement systems and ANCA’s WheelServer ensures every grinding wheel pack is ready to perform—no guesswork, no rework. The result: 20 percent less downtime, 10 percent less rework, and consistently perfect tools on the first try.
Zoller celebrated its 80th anniversary recently at its North American headquarters located in Ann Arbor, MI, with a three-day open house. The celebration brought together manufacturers, partners, industry leaders, as well as members of the media, to explore the future of smart manufacturing while honoring the company’s legacy of innovation, precision, and customer-driven solutions. The event featured immersive technology demonstrations, expert-led presentations, and customer success stories that illustrated the benefits of Zoller solutions, from CAM to part.
Siemens offered a new automation solution for the multi-tasking job shop during Automate 2025 in Detroit. The demonstration involved a digital twin of the software and programming of Sinumerik 828 CNC, working in tandem with a KUKA robot, to simplify the operation and programming in part handling for the operator.
GWJ Technology GmbH has released a new version of its TBK desktop calculation solution for designing, recalculating and optimizing gears, shafts, bearings, bolted joints, shaft-hub connections and other machine elements.
The new KISSsoft Release brings innovations and enhancements for results visualization, allowing you to design even more efficiently, precisely, and productively. Within Gleason’s strategy "Design– Manufacturing – Measure", KISSsoft continues to add functions for simulating cylindrical gear manufacturing. After all, you target a gear design combining the highest strength with low manufacturing costs. KISSsoft offers a variety of rating procedures. Additionally, bearing ratings methods according to Timken have been added.
This year marks an important milestone as Gleason Corporation celebrates its 160th anniversary. Founded in 1865 by William Gleason, the company has transformed from a small workshop to a global leader in gear technology, offering comprehensive solutions that encompass design software, manufacturing and metrology equipment, tooling, aftermarket services, and an extensive training program.
Star Cutter Company launched the FLX machine in 2024, powered by NUM’s advanced FlexiumPro CNC control system with NUMROTO software to easily program all kinds of different tools. This significant advancement underscores Star Cutter’s commitment to delivering cutting-edge solutions for high-volume tool manufacturers, providing an enhanced platform for automated, high-precision manufacturing.
B&R – a division of ABB – introduces Safety+, an innovative open approach to programming safety functions. Developers can now also use the latest software engineering tools and methods for safety applications. An innovative data structure with a digital fingerprint makes the source code freely accessible while also meeting the special requirements of functional safety. In this way, B&R has overcome an obstacle that was previously a barrier to innovation in safety programming.
The KISSsoft System Module is a user-friendly tool also for load spectrum calculation designed for gearboxes. It incorporates nominal boundary conditions, variable forces on shafts, gear shifts, and hence changes in the power flow and operating mode variations. This complexity allows comprehensive calculations based on actual operating data, such as vehicle simulations or in situ measurements.
Verisurf Software, Inc. demonstrated its new Machine Tool Probing (MTP) suite at IMTS 2024. The solution is designed to support in-process inspection directly on CNC machine tools. As the only CAD/CAM-based metrology software on the market. Verisurf continues to build on its heritage of intelligent Model-Based Definition (MBD) with new features, enhancements, and optimized workflows for inspection, reporting, reverse engineering, tool building, and guided assembly.
Unisig’s next-generation operating system further improves the human-robot interface and slashes programming times. The new operating system, featured on Unisig’s UNE6-2i-750-CR small-diameter gundrilling machine, streamlines the setup of dozens of different part handling combinations to reduce new part setup times by 80% or more. The system significantly improves the communication between the machine’s human machine interface (HMI) and the robotic controller. This enables centralized data storage or a single source of truth -– the coding and data for the gundrilling operation and the program for the part handling are stored together for ease of recall.
Rego-Fix has launched a new online product-finder resource, which allows U.S. manufacturers to quickly and easily find and purchase the Rego-Fix solution that best meets their application needs. Using a variety of search criteria, users can find and learn more about the full lineup of products.
Schunk expands digital planning options for automated solutions with two new tools for designing and configuring linear modules. This easy access to expert knowledge is a further step towards offering customers an uncomplicated and secure way to customize design and quickly integrate it into the system planning.
Effective July 1st, 2024, Dr. Ulrich Kissling, founder and Managing Director of KISSsoft AG steps down as Managing Director of KISSsoft AG as he partially transitions to retirement. Dr. Kissling will continue with KISSsoft AG focusing on representation for Gleason / KISSsoft AG on various technical committees and providing technical support to the Engineering and Sales teams.
Engineers Assemble. If you’re a product engineer in charge of designing the latest and greatest manufacturing creations, it’s officially “Tony Stark” time. If Philip K. Dick is more your speed over the Marvel Cinematic Universe, than how about “Tom Cruise” time in Minority Report? Siemens and Sony recently introduced a solution that combines the Siemens Xcelerator portfolio with Sony’s new XR head-mounted display (HMD), SRH-S1—designed using Siemens’ own NX software—insert chicken vs. egg debate here.
GWJ Technology GmbH has presented a new version of its desktop solution TBK with numerous enhancements, particularly in the field of gearing. The TBK calculation software has been used successfully worldwide for more than four decades to dimension gears, shafts, connections, bearings, and other machine elements as well as complete gearboxes. With its various interfaces to 3D CAD systems, the TBK software is a powerful calculation tool for development, design, work planning, production, and quality assurance.
Although gears have been indispensable components in various areas such as mechanical engineering, the automotive industry and industrial gear production for many decades, increasing requirements and current market developments are constantly presenting the drive technology sectors with new challenges. The aim of the Aachen Conference on Gear Production is an exchange of knowledge and experience between engineers who work in or are responsible for the design, development, production, assembly and application of gears.
For wind turbine main gearboxes (MGBs) with about 1 MW or higher power, gearbox designs with multiple power paths are used. They handle several mega-Newton-meter of torque economically. Earlier wind turbines with lower power ratings used parallel shaft gearboxes with only one power path but soon they were superseded by planetary gearboxes having typically three to five planets per stage. This paper describes experiences using planetary gears where “Flexpins” are used to improve the load sharing between the individual planets—representing the multitude of power paths—and along the planet’s face width.
Siemens Digital Industries Software announced it is adding accelerated pre-silicon development in the cloud to its hardware assisted verification product offering with PAVE360 software for Software Defined Vehicles (SDV). The solution is the first accelerated simulation environment to support the new Arm Cortex-A720AE CPU semiconductor IP, launched in March 2024.
This comprehensive four-day training course blends gear theory and practical experience. Participants will learn about the KISSsoft interface, cylindrical gear theory and strength calculation methods, using the shaft and bearing module, optimization of cylindrical gear macro and micro geometry, verification in Loaded-Tooth Contact Analysis (LTCA), and an introduction to the new system analysis tool, KISSdesign. This course includes a tour of the Gleason Works Rochester facility to experience practical examples on the shop floor.
As a community, we gear engineers collaborate and share ideas to progress our collective capability. Technology progresses based on our efforts, and we have seen solid advances in the performance of our products as they become quieter, cheaper, more efficient, and more power dense. The pages of this magazine (past and present editions) are filled with examples where talented engineers have dug deeper into a subject using a more precise approach to a particular area concerning gear performance. The implied belief is always that greater precision (complexity) in the calculations brings greater accuracy (alignment with reality).
Open Mind Technologies, a leading developer of hyperMILL CAD/CAM software solutions worldwide, announced it has joined the Georgia Tech Manufacturing 4.0 Consortium. The consortium is a membership-based organization that facilitates key collaborations between industry, academia, and government to develop and deploy advanced manufacturing technologies as well as provide workforce development. Initial members have contributed funding, technology, and skilled resources supported by the staff at the Georgia Tech AI Manufacturing Pilot Facility located in Atlanta, GA.
UK-based PTG Holroyd has announced that going forward, all models in its TG Series of ultra-precise helical rotor and thread grinding machines will be equipped with the Siemens digitally native Sinumerik One CNC as standard.
This paper presented some steps to get more insight into the effect of meshing damping on the dynamic response and noise emission of a two-stage gearbox transmission system. For this purpose, two variants of the model with different gear materials, one with plastic gears and one with steel gears, were considered. Both variants were designed for the same number of cycles of operation with similar root and flank safeties. The forced response analysis of the models was carried out and the exciting reaction bearing forces were calculated to evaluate which model can achieve better NVH characteristics results with lower noise emission from the housing.
With the release of the new Zeiss Inspect 3D metrology software, Zeiss offers its Industrial Quality Solutions customers numerous new functions. Zeiss Inspect Optical 3D is the solution for the inspection and evaluation of 3D measurement data. With this release, data acquisition is further accelerated and evaluation functions are further improved. The new Autosurfacing app also automatically converts scan data into a high-precision CAD model.
Verisurf Software, Inc. introduces a new sales platform where customers can source new and pre-owned CMMs powered by Verisurf software. All machines are calibrated and certified and include Verisurf CMM Programming and Inspection Suite software.
Clean energy employees are the heart and soul of the industry and keeping them safe is a top priority. American Clean Power's (ACP’s) Operations, Maintenance and Safety Conference (OMS) is the place where leaders from headquarters to the field come together to talk about retention strategies, recruitment techniques and training best practices in an effort to make clean energy stronger and safer. Key exhibitors include Applied Industrial Technologies, ExxonMobil, Intertek AIM, ONYX Insight, Shell Lubricants, Vestas and more. The event takes place in San Diego at the Manchester Grand Hyatt.
Gleason's Coniflex® Pro Design and Manufacturing System for producing stronger, quieter, and more reliable e-drive differential gears in high volumes, for automotive, truck, bus and off-highway transmissions. It‘s the differential difference!
To ensure all customers and their machines benefit from digital assistance, GF Machining Solutions (GFMS) has launched their new My rConnect platform engineered for the company’s EDM, milling, and laser texturing machines. The all-encompassing platform allows shops to connect any model of GFMS machine for fast, responsive, and easily accessible service and support while also providing expanded digital capabilities.
Sandvik has signed an agreement to acquire esco GmbH engineering solutions consulting, a German-based supplier of software for power skiving, an important technology within gear machining. Esco’s software solutions supports design, production and quality inspection in the main area of gear manufacturing. The company will be reported in Sandvik Coromant, a division within Sandvik Manufacturing and Machining Solutions.
Marposs provides solutions that guarantee quality and process control to the whole production cycle. Starting from the part machining, to final quality checks and now also providing an industrial software solution to monitor, analyze, and improve the quality and efficiency of industrial production.
This article describes a cloud-based process and machine component monitoring system called ARGUS. The term “swarm” is used for a large population of gear-grinding machines of individual and independent customers connected to the ARGUS system and the ARGUS cloud. These “swarm” machines permanently feed their anonymized process data into a common cloud database. Reishauer uses this database for big data analytics to discover patterns that indicate successful process and machine component behavior patterns worth integrating into the ARGUS algorithms and propagate them across the complete ARGUS customer base.
2023 is shaping up to be our planet’s hottest year on record, and the wind energy industry is feeling the heat. The GWEC (Global Wind Energy Council) says that the rate of wind turbine installations will need to quadruple globally by the end of the decade if we’re to achieve the IRENA’s (International Renewable Energy Agency) goal of net zero carbon emissions by 2050—and keep the average annual temperature worldwide from increasing more than the predicted 1.5° C. Fortunately, “net zero” commitments are gathering global momentum. Before year’s end, total global windpower is expected to reach a historic milestone of 1 TW of installed capacity, eliminating 1.2 billion tons of CO2 annually, roughly the equivalent of all the carbon emissions of South America.
United Grinding Group offers digital assistance systems that make work easier for users of all kinds in areas like remote service, service monitoring, production monitoring, and digital solution technologies. Remote Service offers simple and fast assistance. For example, in the event of machine downtime, United Grinding North America customers can request service with the press of a button. This service request can be submitted by the customer via a smartphone and the corresponding Digital Solutions app, or via the Customer Cockpit.
Verisurf Software Inc. and Accurate Gauging and Instruments, Ltd have signed a joint sales and support agreement to represent Verisurf Software in India. Under the agreement, the two companies will work together to provide complete Advanced metrology solutions to manufacturers and global supply chain partners.
It’s rare to find employees who work 25 years at the same company, especially in the volatile software industry. That’s why Global Shop Solutions, a leading provider of ERP software for manufacturers, is proud to announce the 25th anniversary of Mike Melzer, Vice President of Operations & Service.
Verisurf Software, Inc. announces its 2024 software release providing new productivity workflows, powerful tools, enhanced functions, and expanded sensor and device compatibility, all designed to better connect metrology and manufacturing for global success.
Verisurf Software, Inc. announces support for the Renishaw RUP1 (REVO Ultrasonic Probe), providing an ultrasonic thickness probing solution to automate the measurement and reporting of thickness requirements.
Ceratizit’s Executive Director of Technology and Solutions, Mark Blosser, has been selected to present at Siemens Realize LIVE U.S. conference in Las Vegas, Nevada, June 12–15, 2023. The conference is Siemens’ flagship event focusing on advances and best practices in digital transformation.
Machine Tool Builders Inc. has introduced a comprehensive new recontrol/retrofit package for larger-capacity profile grinding gear machines with outdated controls that add highly desirable performance at a fraction of the cost for new machinery.
Verisurf 2024 is the latest release of the popular measurement software for automated quality inspection, reporting, scanning, reverse engineering, tool building, and assembly guidance. The software is powerful, flexible, and easy to use for measurement applications across the manufacturing enterprise.
In the fast, cost-effective, sustainable future, smart software is paving the way to optimized production and improved decision making. Digital technology and smart software have already transformed the machining industry with unprecedented access to actionable data for better results in less time. With a wealth of data generated from production processes of all kinds, shops need to understand how to use that data to their advantage. Now, progressive manufacturers can move toward even greater benefits with software that fulfills the promises of Industry 4.0.
Wind power has emerged as one of the most important sources of renewable energy in recent years. The global wind power capacity was estimated to be 837 gigawatts in 2021 (statista.com). In the United States alone, wind is the largest source of renewable electricity, providing 10.2 percent of the country’s electricity and still growing (cleanpower.org/facts/wind-power/). However, to ensure maximum power generation, the efficiency and reliability of the wind turbine are critical.
In this interview, we learn about Gleason Plastic Gears (GPG), a division of Gleason Corporation that specializes in designing and manufacturing plastic gears using their proprietary no-weldline technology. GPG has diversified its customer base and serves various industries such as automotive, medical, electronics, home and leisure, marine, education, and hobby. The interview covers topics such as the advantages of the no-weldline technology, surprising applications where plastic gears are replacing metal gears, promising materials and methods for the future of plastic gears, challenges faced by plastic gear designers, and recent developments in services, software, and manufacturing technology.
Mitsubishi Heavy Industries EMEA—Duisburg Branch today announced a new contract with global software provider Energy Exemplar to support their sales, business development, and project development teams. The branch office based in Duisburg, Germany focuses on the growth of MHI’s energy transition-related business, supporting the decarbonization of industry.
Cleanpower 2023 (New Orleans) unites the most knowledgeable minds in clean energy to chart the future of this powerful industry and discuss the opportunities ahead. As previous attendees attest, the conference grows clean energy businesses by gathering key decision makers and stakeholders across the wind, solar, storage, hydrogen, and transmission industries for discussion, deal making, networking and fun.
Two Forest City Gear employees, CNC Supervisor Mike Miller and CNC Lead/Programmer Josh Gates, recently attended a four-day training retreat in Pfronten, Germany hosted by DMG MORI. The event featured various seminars and opportunities for guests to experience firsthand DMG’s newest equipment and technologies, as well as networking and a taste of German culture.
TN Vaerktoejsslibning, Denmark’s second-largest precision tooling company, is deploying Numroto, the programming system for tool grinding from NUM across its entire production floor. The company cites highly successful long-term experience of the software, together with excellent technical support from NUM, as the key reasons for choosing to standardize on Numroto.
At the CIMT 2023, which takes place from April 10th–15th, WFL will present its technology and software solutions, such as WFL iControl, scanning technologies, or the new operational data acquisition system myWFL. But that is not the end of the story. The actual highlight of the show is the presentation of the M30 Millturn and a machining demonstration of a roots rotor.
The latest version offers a wide range of powerful new features, from a new gear design module, to the influence of the wheel body during a complete rollover, to new display options for 3D images and animation of the gearbox kinematics in reports.
Gleason's e-Drive Days online webinar addresses the specific requirements and challenges of e-Drive transmission manufacture, with particular attention to minimizing gear noise. The event showcases the latest developments in design, simulation, cutting and hard finishing, as well as suitable inspection and analysis tools to achieve most efficient and quiet gears. Day one examines gearbox design and optimization; day two looks at the manufacturing of e-Drive gears; day three offers in-process inspection and gear noise analysis.
Why is the industry considering changing from well-established gear manufacturing processes to something that is much more complex at first glance? Gear manufacturing has been its own “world” in metal cutting, dominated by companies with very specific expertise around gear technology. Production output has been high, but flexibility is limited. The technicians running these machines are highly skilled, but recruiting new staff with these skill sets has become more and more difficult.
State of the Gear Industry Perspectives takes an in-depth look at the challenges and opportunities in gear manufacturing today and in the future. Our sixth installment online is an interview with Shane Hollingsworth, vice president of sales, Kapp Technologies.
State of the Gear Industry Perspectives takes an in-depth look at the challenges and opportunities in gear manufacturing today and in the future. Our first installment online is an interview with Udo Stolz, vice president of sales and marketing at Gleason Corporation.
In the KISSsoft training program until summer 2023, you will find introductory training courses, advanced training courses and special training courses on selected topics. KISSsoft will be offering training in Bubikon, Switzerland and live streams, which will allow you flexibility and planning security, as well as the opportunity to interactively ask questions and participate in discussions in a virtual setting.
In the KISSsoft training program until summer 2023, you will find introductory training courses, advanced training courses and special training courses on selected topics. KISSsoft will be offering training in Bubikon, Switzerland and live streams, which will allow you flexibility and planning security, as well as the opportunity to interactively ask questions and participate in discussions in a virtual setting.
In the KISSsoft training program until summer 2023, you will find introductory training courses, advanced training courses and special training courses on selected topics. KISSsoft will be offering training in Bubikon, Switzerland and live streams, which will allow you flexibility and planning security, as well as the opportunity to interactively ask questions and participate in discussions in a virtual setting.
In the KISSsoft training program until summer 2023, you will find introductory training courses, advanced training courses and special training courses on selected topics. KISSsoft will be offering training in Bubikon, Switzerland and live streams, which will allow you flexibility and planning security, as well as the opportunity to interactively ask questions and participate in discussions in a virtual setting.
In the KISSsoft training program until summer 2023, you will find introductory training courses, advanced training courses and special training courses on selected topics. KISSsoft will be offering training in Bubikon, Switzerland and live streams, which will allow you flexibility and planning security, as well as the opportunity to interactively ask questions and participate in discussions in a virtual setting.
Marposs OptoCloud EDU (Electric Drive Unit) is the latest generation of 3D precision inspection solutions, designed for the Electrical Vehicle Industry and its unprecedented quality assurance processes. OptoCloud EDU is capable to reconstruct the 3D model of complex and articulated workpieces and automatically execute measurements and vision inspection tasks.
With the myWFL operational data acquisition system, you can maintain an overview around the clock and exploit the optimization potential for the smart factory. The software not only has a user-transparent display, but also improves machine utilization. All data in the production environment is collected and analyzed to achieve higher productivity. Shorter production times and a more effective design of the Smart Factory processes thus go hand in hand.
The performance of an Electric Vehicle Power Unit is directly connected with critical tolerances. Tolerances drive opportunities for performance enhancement with cost reduction. The tests normally used to determine and validate tolerances are both expensive and time consuming with prototype parts. By replacing the initial tests with Digital Twin simulations, results can be obtained quickly, and at a much lower cost. This article discusses one of these tests and the results.
Variable loads resulting from a working process, starting process, or operation near a critical speed will cause varying stresses at the gear teeth of a drive system. The magnitude and frequency of these loads depend upon the driven machine, the motor, the dynamic mass elastic properties of the system, and other effects.
Electric vehicles could represent up to 70% of all cars by 2050. To ensure the acceptance of their vibrational and acoustical characteristics, profound NVH analysis is the key to minimize vehicle excitations caused by specific e-drive transmission designs.
Automation tasks are becoming ever more challenging. Using intelligent software in combination with the relevant automation solutions not only enables workpieces to be loaded and unloaded but also means that machine tools can be set up fully automatically through automatic replacement of tools and clamping devices. FRAI strives to be an innovative automation partner and is therefore developing highly flexible robot systems to respond to this trend. Concepts such as the mobileCELL are a complete first and enable a wide range of expansion stages, making them as future-proof and competitive as possible.
Marposs has announced MAINDO, its new digital platform that integrates Marposs monitoring, measuring, testing or other manufacturer device/solutions throughout the entire production process, combining quality and process into a holistic production monitoring view.
IFPE, the International Fluid Power Exposition, is the leading North American exhibition bringing together the fluid power, power transmission and motion control industries. IFPE is co-located with CONEXPO-CON/AGG, held at the Las Vegas Convention Center.
PowerGen is the largest network and business hub for electricity generators and solution providers engaged in power generation. Power producers, utilities, EPCs, consultants, OEMs, and large-scale energy users gather at PowerGen International to discover new solutions as large, centralized power generation business models evolve into cleaner and more sustainable energy sources
In this latest edition, issue 9, of the GEARS inline Customer Magazine, Klingelnberg once again presents all sorts of trends and innovations from the world of gears. This time, the machine manufacturer focuses primarily on the hot topic of noise behavior and analysis.
At AMB 2022, WFL Millturn Technologies will be presenting the new M20 MILLTURN complete machining center for the first time. Alongside gear skiving technology, there is clear trend toward automation and the integration of sensors. The latest solutions from WFL range from smart software to screw programming through to intelligent tools and clamping devices.
Forming tools are expensive, often made from carbide and tool steel. Carbide grinding is often the first choice today because customer requirements have increased and continue to increase in terms of complexity, dimensional accuracy and reproducibility. Apart from that, production must also be significantly more economical.
System-supplier Klingelnberg will be back at AMB (Booth C41, Hall 5), where it will be highlighting solutions for smooth-running gearboxes. The exhibit will feature the Höfler Cylindrical Gear Grinding Machine Speed Viper, the Klingelnberg Precision Measuring Center P 40 and the newly developed Höfler Cylindrical Gear Roll Testing Machine R 300.
IMTS visitors can experience live machining with the WFL M50 MILLTURN/3000 mm. The multifunctional turning-boring-milling center is designed for complete machining of complex chuck and shaft parts up to 670 mm swing over bed. Turning, milling, drilling, hobbing, shaping, gun drilling as well as ID machining can be performed under any angle of the tool.
Verisurf Software, Inc. will be demonstrating a universal approach to measurement and inspection at this year’s IMTS Show in Booth #133345. Verisurf software provides measurement and inspection workflows with inspection plans that can be created once and used across the manufacturing enterprise on any portable or fixed CMM.
When it comes to an early identification of noise problems in the drivetrain one has to take data analytics and its integration in the manufacturing process into account. The big vision here, in particular, is preventive quality. By evaluating sensor data of the machining process, it promises to predict whether a gear is ok or not ok.
Mahr Inc. recently introduced a new generation of electronic digital comparators, the Millimess 2000 W(i) and 2001 W(i).The new digital comparators combine practical and reliable operation with maximum precision. Using a unique inductive measuring system, measurements are more precise than ever with added probe linearization—whether it’s a static or dynamic measurement task.
Mitutoyo America Corporation is pleased to announce the release of the Quick Vision Pro Series, the latest generation of Mitutoyo Vision Measurement Systems. Quick Vision Pro Series machines are packed with high-performance technologies that greatly improves 3D non-contact measurement and productivity. This highly advanced non-contact measuring system delivers even more speed, efficiency, and versatility to the Mitutoyo Vision Measurement line.
The MAZATROL SmoothEz CNC from Mazak has a graphical, intuitive programming mode that minimizes the use and understanding of G-codes. Users answer conversationally displayed questions about the workpiece, and the control constructs the program automatically.
At IMTS 2022 in Booth #135621, Marposs will be demonstrating OptoCloud EDU (Electric Drive Unit), its latest generation of 3D precision inspection solutions designed for the electrical vehicle industry. Using multiple laser heads in tandem with contact sensors for measurement and vision inspection, OptoCloud EDU reconstructs the 3D model of complex and articulated workpieces in less than a minute to ensure accuracy of the produced component. For example, it can validate 240 electrical contacts of a motor stator in only 30 seconds, which is 100 times faster than a traditional contact system.
AddUp, a joint venture created by Michelin and Fives, is a global metal additive manufacturing OEM and service provider of powder bed fusion (PBF) and directed energy deposition (DED) technologies. They have launched a suite of new process monitoring software to bolster the capabilities of the FormUp 350 PBF machine: AddUp Dashboards, Recoat Monitoring, and Meltpool Monitoring. This new software suite for its metal 3D printing technology optimizes part quality for prototyping and end-use industrial applications.
Star Cutter Company will be displaying its newest generation automated NXT 5-axis tool grinder in Booth #237013 at IMTS 2022 featuring detailed graphics that enable visitors to take a self-guided tour of the machine, which will be shadow grinding during the show. The display system will feature the 28 kW spindle option and four-station wheel change capability. It will be equipped with a robot loader and flat blade/insert clamping fixture for live demonstration of automated production. Videos to showcase tooling for form cutters, boring bars and medical hip rasps will also be on display.
At IMTS 2022, United Grinding North America will be featuring the STUDER S131r cylindrical ID-radius grinding machine for I.D. grinding operations where maximum precision is paramount.
Verisurf Software, Inc. announces the Verisurf Engine Builder Performance Package, a complete 3D measurement software, hardware, training, and support package for reverse engineering, designing, building, and verifying high-performance engines and components
Aircraft engines can be made more efficient by integrating planetary gears. In such an application, the planetary gears experience very high load cycles under fully reversed bending loads. Pulsator test rigs, which nowadays offer the possibility to perform UHCF investigations, can only be used for purely pulsating loading of gears. Therefore, for the investigation of the UHCF tooth root load carrying capacity under fully reversed bending load, a back-to-back test rig is required. Back-to-back test rigs usually have speeds of n = 3,000 rpm, which makes investigations in the UHCF range take a very long time. Therefore, a high-speed back-to-back test rig was developed.
LK Metrology, Inc. will be exhibiting a variety of new products in Booth #135230 in the East Building, Level Three at McCormick Place in Chicago, IL for the 2022 IMTS Show, September 12-17, 2022.
Verisurf Software, Inc. announces support for the new Hexagon, Leica AT500, and B-Probe plus CMM. Verisurf interfaces with Leica Laser Tracker Systems for data collection and 3D measurement workflows, including alignments, inspection, tool building, assembly, scanning, analysis, reporting, automation, and reverse engineering.
Hexagon’s Manufacturing Intelligence division recently announced the winners of its first cohort of start-ups selected to help the manufacturing industry operate more sustainably and efficiently. The company launched its Sixth Sense open innovation platform in January 2022 to challenge how multinationals approach innovation and help nurture creative solutions to emerging manufacturing challenges by connecting with world-class companies to solve some of humanity’s biggest challenges.
The L.S. Starrett Company has enhanced its AVR300 Multi-Sensor Vision System with a large 2.36" (60 mm) FOV-dedicated 0.14x telecentric lens for micron-level resolution and accurate field-of-view (FOV) measurements. This is the largest FOV to date for Starrett. IMTS attendees can see the AVR-FOV at Booth #135044 located in the Quality Pavilion, East Hall in McCormick Place, Chicago IL from Sept 12- 17, 2022.
Wintriss Controls Group has announced it will be demonstrating new, advanced features in its ShopFloorConnect OEE and Data Collection Software at IMTS Booth #135073 located in the East Building, Level 3, in McCormick Place, Chicago IL from Sept 12- 17, 2022.
Hexagon offers a three-part E-mobility webinar series highlighting the use of engineering simulation tools and methods to rapidly evaluate numerous ePowertrain designs. This webinar series will showcase how an EV gearbox is designed from scratch and developed to meet design requirements.
Addit3D-International Additive Manufacturing and 3D Fair (Barakaldo, Spain) will feature almost 230 products, services and innovations. Exhibitors include advanced systems and machinery and 3D printing, equipment and printers, industrial applications, raw materials, consumables, 3D printing services, software, 3D scanners, and R&D and training
IBS Quality GmbH has launched the new PAM-System (Portable Automated Measurement System), a portable cobot-based 3D scanning and measurement solution, at Control, Stuttgart, Germany, May 3 -6, Hall 3, Stand 3312. The launch is in collaboration with Verisurf Software, Inc., and its integrated 3D measurement software for automated quality inspection, reporting, scanning, and reverse engineering.
Verisurf Software, Inc. will be demonstrating Verisurf 2023 at Control, Stuttgart, Germany, May 3 -6, Hall 3, Stand 3312. Verisurf 2023 continues to refine metrology workflows with added features designed to reduce time and improve the efficiency of automated quality inspection and reporting, scanning, reverse engineering, and tool building.
With its brand-new 300GMS nano Gear Metrology System, Gleason presents a world- first at Control Show 2022, May 03-06, Stuttgart, Germany. The capability of measuring gears at sub-micron level, executing advanced waviness analysis and evaluating gear noise using the most advanced analytical tools, make the 300GMS nano ideally suited to support automotive e-drive production with minimum noise requirements.
As part of a $2 million National Science Foundation Grant, robots from Kuka Robotics are helping the University of Michigan (U of M) advance research that could result in robots working side-by-side with humans on building construction sites. The research involves three KUKA KR Quantec robots along with the company’s robot sensor interface (RSI) software, all of which will allow human workers to use interactive task learning technology to teach the robots to perform construction tasks.
KISSsoft is a well-known software system that addresses gear manufacturing as a holistic process. With over 4,000 licenses sold worldwide, its functionality is dedicated to gear manufacturing and gear inspection and makes it easier for engineers—in the areas of calculation, manufacturing, and quality assurance—to collaborate and exchange data.
The company esco, a technology partner for process digitization in the gear and cutting tool industry, is adding a technology module to its software for the Power Skiving process chain.
Gleason's special online event from April 26-28, 2022 is all about design, manufacturing and inspection of e-drive gears. KISSsoft will look at several aspects of gear design in an EV system environment.
Heidenhain’s new PlantMonitor is a digital solution to aid the manufacturing shop floor. Now available for companies interested in simultaneously monitoring and analyzing production data at multiple sites utilizing machine tools where at least one is equipped with a Heidenhain TNC control/StateMonitor software combination per site, this new PlantMonitor can aggregate the data onto one screen for review. Machine tools using even non-Heidenhain controls can be included and monitored.
KISSsoft Release 2022 will be launched in June. The beta release, available now, gives users a first impression of the new KISSsoft features and includes numerous new software functionalities.
Virtual prototyping (VP) is an area where huge advances have been made. As gear and transmission systems, and the methods of their production, become more complex and more interdependent, finding ways to use VP across the entire development process—from the initial design, through analysis, right up to manufacturing—ultimately means gaining a better understanding of system performance and efficiency.
Gear noise is a common evil any gear manufacturer must live with. It is often low enough not to be a major problem but, at times, gear whining may appear and then, tracking the source and, especially, curing the ill can be tricky at best.
The design of gear blanks or flanges has traditionally been driven by weight reduction. Recently innovative companies have started to use the gear blank design to tune the system dynamics to reduce gear whine.
Due to production by pressing and sintering, PM gears are porous. Since pores reduce the loaded area and are also probable crack initiators, the porosity determines the strength of the PM component. PM gears can be densified to increase their local density and, therefore, the load-carrying capacity. PM gears are compacted locally since they are mainly loaded directly at the surface. A common process to densify PM gears locally is the cold rolling process. The contact conditions in the cold rolling process determine the density profile and, therefore, the material properties of the PM component. The influence of the contact conditions in cold rolling of PM gears on the resulting density profile is yet to be investigated.
The Corpus Clock has a hundred and one little interesting factoids about everything from its design to its unveiling to its message — and it’s just hanging out on a street corner in Cambridge.
It's more important than ever to understand the full system your individual components are going into. Here's the latest in how software developers are helping you do that.
REANY is software for the evaluation of
gears and splines that have been measured
completely on all teeth. It is suited
to both quality assessment and analyzing
the causes for deviations. REANY is
short for Reality Analysis.
A key part of gear design software development is customer feedback. With the right feedback, you can get your software developer to work for you to provide the most relevant features possible.
Gear designers face constant pressure to increase power density in their drivetrains. In the automotive industry, for example, typical engine torque has increased significantly over the last several decades. Meanwhile, the demands for greater fuel efficiency mean designers must accommodate these increased loads in a smaller, more lightweight package than ever before. In addition, electric and hybrid vehicles will feature fewer gears, with fewer transmission speeds, running at higher rpms, meaning the gears in those systems will have to endure life cycles far beyond what is typical with internal combustion engines.
The aim of the study was to apply such a specialized tooth contact analysis method, well-used within the steel gear community, to a polymer gear application to assess what modifications need be made to these models for them to be applicable to polymer gears.
A high number of wind turbine gearboxes do not meet their expected design life, despite meeting the design criteria of current bearing, gear and wind turbine industry standards and certifications.
More than 100 years ago, gear
manufacturers were facing
a significant challenge from
industry. The incredible advances in
industrialization and transportation that
occurred at the turn of the 20th century
resulted in incredible growth for gear
makers, but there were significant technical
issues. "The lack of process and product
standardization was a continuing
problem in all U.S. industry. The lack
of industry-wide gear standards meant
there were no standard gear tooth sizes,
ratings, quality definition or consistent
manufacturing methods" (Celebrating
100 Years of Gearing, pg. 22).
In a capitalist society, the way things usually work is that government
and academia focus on research and
development, while industry focuses
on commercialization. The result
is an increasingly wide disconnect in
the applied research sector, which deals
primarily with technology development
and demonstration.
There's no substitute for a good
software package in gear manufacturing.
It's a critical shop floor tool
that provides practical engineering services
that customers appreciate. When
you're in the business of specifying and
procuring high quality gears, the software
needs to meet many objectives including
the consideration of all tolerances of
center distance, tooth thickness and tip
diameters, root diameters, fillets, etc. It's
also imperative that the software updates
include the latest revisions to the gear
standards being used in the industry.
This paper demonstrates an application of the tooth interior fatigue fracture (TIFF) analysis method, as implemented in SMT's MASTA software, in which loaded tooth contact analysis (LTCA) results from a specialized 3-D contact model have been utilized to determine the load boundary conditions for analysis of tooth flank fracture (TFF).
Having read about an automobile race in France, Kohlsaat
decided he'd host America's first auto race in Chicago. The year
was 1895 and automobiles were still a great curiosity. Kohlsaat,
owner/publisher of the Chicago Times Herald, planned to exploit
the growing interest in motoring by sponsoring a 54-mile race
from downtown Chicago to nearby suburb Evanston, Illinois,
and back. The match was open to all comers, foreign or domestic,
whether powered by gas, electricity, or steam. The top prize:
$2,000 (that's 50,000 2016 dollars).
Schafer Gear Works greatly reduces gear inspection queue time and adds precious capacity by installing Gleason's
new "shop-hardened" 300GMS P gear inspection system.
This paper outlines the comparison of
efficiencies for worm gearboxes with
a center distance ranging from 28 -
150 mm that have single reduction from
5 to 100:1. Efficiencies are calculated using several standards (AGMA, ISO, DIN, BS) or by methods defined in other bibliographic references. It also deals with the measurement of torque and temperature on a test rig — required for the calibration of an analytical model
to predict worm gearbox efficiency
and temperature. And finally, there are examples of experimental activity (wear and friction measurements on a blockon- ring tribometer and the measurements of dynamic viscosity) regarding the effort of improving the efficiency for worm gear drivers by adding nanoparticles of fullerene shape to standard PEG lubricant
I'd like to apologize to the dedicated people working on revisions to the AGMA 925 standard and the Technical Report ISO 15144-1, both of which deal with the issue of micropitting. In the
March/April issue of Gear Technology, we published an opinion piece in our Voices column that harshly criticized the methods for predicting micropitting outlined in ISO 15144-1.
Plastic gears are everywhere
today - throughout your car, at
the oceans' lowest depths, in deep
space. The question, when is a
metal gear a candidate for plastic
conversion, can be addressed in
three words, i.e. what's the application?
In order to properly select a grease for a particular application, a sound knowledge of the influence of different grease components and operating conditions on the lubrication supply mechanism and on different failure modes is of great benefit.
Over the last 15 years, there has been
significant growth in the number of
transmission types as well as their complexity: manual, conventional automatic, dual clutch, automated manual, continuously variable, split power and pure EV transmissions.
A transverse-torsional dynamic model of a spur gear pair is employed to investigate the
influence of gear tooth indexing errors on the dynamic response. With measured long-period
quasi-static transmission error time traces as the primary excitation, the model predicts
frequency-domain dynamic mesh force and dynamic transmission error spectra. The dynamic
responses due to both deterministic and random tooth indexing errors are predicted.
Developed here is a new method to automatically find the optimal topological modification from the predetermined measurement grid points for bevel gears. Employing this method
enables the duplication of any flank form of a bevel gear given by the measurement points and the creation of a 3-D model for CAM machining in a very short time. This method not only
allows the user to model existing flank forms into 3-D models, but also can be applied for various other purposes, such as compensating for hardening distortions and manufacturing deviations which are very important issues but not yet solved in the practical milling process.
Since we began publishing in 1984, Gear Technology's mission has been to educate our readers. For 31 years, we've shown you the basics of gear manufacturing as well as the cutting edge. We take our educational mission quite seriously, and we go through steps that most publishers don't have time for or wouldn't consider.
Here is some history that bears repeating - or at least re-reading. So take a few minutes to give it up for a long-gone Brit named Henry Maudslay
(August 22, 1771 - February 14, 1831) - also known as "A Founding Father of Machine Tool Technology." You might
also consider him an early leader in inspection, as he also invented the first bench micrometer capable of measuring to one ten-thousandth of an inch.
At the dawn of the Industrial
Revolution, so-called mechanics
were tasked with devising the precise methods that would make mass production possible. The result was the first generation of machine tools, which in turn required improved tooling and production methods.
Gears with a diametral pitch 20 and
greater, or a module 1.25 millimeters
and lower, are called fine-pitch or low-module gears. The design of these gears has its own specifics.
So there is little chance that they need the same software to assist with their work. Gone are the days when companies wrote their own code and process engineers thumbed the same tattered reference book.
The face load factor is one of the most important items for a gear strength calculation. Current standards propose formulae for face load factor, but they are not always appropriate. AGMA 927 proposes a simpler and quicker algorithm that doesn't require a contact analysis calculation. This paper explains how this algorithm can be applied for gear rating procedures.
On April 7th, the industrial fair in Hanover opens its doors. At the same time, the new version of KISSsoft 03/2014 will be released with a number of innovations that have been implemented...
Siemens' NX software, the company's flagship solution for integrated 3-D computer-aided design, manufacturing and engineering analysis (CAD/CAM/CAE), is now available...
Light-weight construction and consideration of available resources result in gearbox designs with high load capacity and power density. At the same time, expectations for gear reliability are high. Additionally, there is a diversity of planetary gears for different applications.
For metal replacement with powder metal (PM) of an automotive transmission, PM gear design differs from its wrought counterpart. Indeed, complete reverse-engineering and re-design is required so to better understand and document the performance parameters of solid-steel vs. PM gears. Presented here is a re-design (re-building a 6-speed manual transmission for an Opel Insignia 4-cylinder, turbocharged 2-liter engine delivering 220 hp/320 N-m) showing that substituting a different microgeometry of the PM gear teeth -- coupled with lower Young’s modulus -- theoretically enhances performance when compared to the solid-steel design.
For two days in Saline, Michigan,
Liebherr's clients, customers and
friends came together to discuss the latest gear products and technology. Peter Wiedemann, president of Liebherr Gear Technology Inc., along with Dr.-Ing. Alois Mundt, managing director, Dr.-Ing. Oliver Winkel, head of application technology, and Dr.-Ing. Andreas Mehr, technology development shaping and grinding, hosted a variety of informative presentations.
Like many Americans, I've been trained with the idea that those who see a problem should be the ones responsible for helping to solve it. If you see
that something is broken, and you know how to fix it, don't wait for your dad, your boss or the government to tell you what to do. Just fix it.
Romax Technology, the gearbox, bearing
and driveline engineering specialist, has launched a new design software package that will increase speed, quality, creativity and innovation when designing gearboxes and drivelines. Called Concept, the new product delivers on the Romax vision of streamlining the end-to-end, planning-to-manufacture process with open, easy to use software solutions. It has been developed in close collaboration with engineers in the largest ground vehicle, wind energy and industrial
equipment companies around the globe.
IMTS exists primarily as a buy-and-sell
North American venue for practically every conceivable technology used in manufacturing, and in that regard it has no equal. There you’ll find on display the latest and greatest technology, from hardware to software and everything in between. But anyone who has attended past shows is aware that IMTS is much more than that. Following is a rundown of "extracurricular" activities you’ll find waiting for your edification
and enjoyment.
It’s a brave, new hardware-software world out there. Players in the worldwide gear industry who don’t have plenty of both run the risk of becoming irrelevant—sooner than later.
The first edition of the international calculation method for micropitting—ISO TR 15144–1:2010—was just published
last December. It is the first and only official, international calculation method established for dealing with
micropitting. Years ago, AGMA published a method for the calculation of oil film thickness containing some comments
about micropitting, and the German FVA published a calculation method based on intensive research results. The FVA and the AGMA methods are close to the ISO TR, but the calculation of micropitting safety factors is new.
India is rapidly turning into a global manufacturing hub, thanks to the country’s manufacturing and engineering
capabilities, vast pool of skilled expertise and its size. These qualities offer it a strategic advantage for the manufacturing segment. A large number of international companies in varied
segments have already set up a manufacturing base in India and others are following suit. It only makes sense to bring this industry segment together under one roof to discuss the current
trends and technology prevalent to the marketplace. IPTEX 2012 is scheduled from February 9–11, 2012 at the Bombay Exhibition Center in Mumbai, India.
Tooth contact under load is an important verification of the real contact conditions of a gear pair and an
important add-on to the strength calculation according to standards such
as ISO, AGMA or DIN. The contact analysis simulates the meshing of the
two flanks over the complete meshing
cycle and is therefore able to consider
individual modifications on the flank
at each meshing position.
Profile corrections on gears are a commonly used method to reduce transmission error, contact shock, and scoring risk. There are different types of profile corrections. It is a known fact that the type of profile correction used will have a strong influence on the resulting transmission error. The degree of this influence may be determined by calculating tooth loading during mesh. The current method for this calculation is very complicated and time consuming; however,
a new approach has been developed that could reduce the calculation time.
Gear manufacturers are moving into an era that will see changes in both engineering practices and industry
standards as new end-products evolve. Within the traditional automotive
industry, carbon emission reduction
legislation will drive the need for higher levels of efficiency and growth in electric and hybrid vehicles.
Meanwhile, the fast growing market of wind turbines is already opening up a whole new area of potential for gearbox manufacturers, but this industry is one that will demand reliability, high levels of engineering excellence and precision manufacturing.
The machine element package by KISSsoft for the design and optimization of components like gears, shafts, bearings and others is now available in the new version 04/2010.
Easily one of the central issues
affecting U.S. manufacturing is what one might call the exports deficit—the inability of American companies to sell products to, for instance, Asian markets, developing countries and other ports of call—due to what they perceive to be unfair trade agreements and or policies.
In this paper, the potential for geometrical cutting simulations - via penetration calculation to analyze and predict tool wear as well as to prolong tool life - is shown by means of gear finish hobbing. Typical profile angle deviations that occur with increasing
tool wear are discussed. Finally, an approach is presented here to attain improved profile accuracy over the whole tool life of the finishing hob.
Gear engineers have long recognized the importance of considering system factors when analyzing a single pair of gears in mesh. These factors include important considerations
such as load sharing in multi-mesh geartrains and bearing clearances, in addition to the effects of flexible components such as housings, gear blanks, shafts and carriers for planetary geartrains. However, in recent years, transmission systems have become increasingly complex—with higher numbers of gears and components—while the quality requirements and expectations in terms of durability, gear whine, rattle and efficiency
have increased accordingly.
A computational fluid dynamics (CFD) method is adapted, validated and applied to spinning gear systems with emphasis on predicting windage losses.
Several spur gears and a disc are studied. The CFD simulations return good agreement with measured windage power loss.
The auction has been held. The warehouse is bare. The computers
and furniture are being packed, and Cadillac Machinery, the company
started by my father in 1950, and of which I was president for more
than 25 years, is close to being no more.
With the right selection of nonstandard center distance and tool shifting, it may be possible to use standard tools to improve the gear set capacity with a considerable reduction in cost when compared to the use of special tools.
A main limiting factor in extending the use of hard coatings to machine component application is the lack of knowledge about how these inert coatings perform under lubricated conditions using today's lubricants.
Romax Technology is automating the design iteration process to allow companies to be faster to market with the highest quality, most robust gear products.
Curved face width (CFW) spur gears are not popular in the gear industry. But these non-metallic gears have advantages over standard spur gears: higher contact ratio, higher tooth stiffness, and lower contact and bending stresses.
Carburized helical gears with high retained austenite were tested for surface contact fatigue. The retained austenite before test was 60% and was associated with low hardness near the case's surface. However, the tested gears showed good pitting resistance, with fatigue strength greater than 1,380 MPa.
Transmission errors, axial shuttling forces and friction result in bearing forces that serve as the major excitations of gear noise. This paper will use these factors as well as gear stresses and tribological factors to assist in obtaining optimal gear designs.
Welcome to Revolutions, the column that brings you the latest, most up-to-date and easy-to-read information about the people and technology of the gear industry.
Bodine Electric Co. of Chicago, IL., has a 97-year history of fine-and medium-pitch gear manufacturing. Like anywhere else, traditions, old systems, and structures can be beneficial, but they can also become paradigms and obstacles to further improvements. We were producing a high quality product, but our goal was to become more cost effective. Carbide hobbing is seen as a technological innovation capable of enabling a dramatic, rather than an incremental, enhancement to productivity and cost savings.
You hardly have to leave your office anymore, because the whole world is being piped right to your desktop. I know, because I recently attended my first seminar by Internet.
Welcome to Revolutions, the column that brings you the latest, most up-to-date and easy-to-read information about the people and technology of the gear industry.
For high-quality carburized, case hardened gears, close case carbon control is essential.
While tight carbon control is possible, vies on what optimum carbon level to target can be wider than the tolerance.
When you to to IMTS, you expect to see hoopla. The mass of machines and bodies gathered in one place should create an unmistakable level of energy and enthusiasm. IMTS 2000 seemed uncharacteristically quiet...
Gears are extremely complex shapes. Coordinate measuring machines, or CMMs, are designed to measure complex shapes. It seems to follow that CMMs world, therefore, be the ideal tool for measuring gears. But the answer is not so simple.
Welcome to Revolutions, the column that brings you the latest, most up-to-date and easy-to-read information about the people and technology of the gear industry.
Fig. 1 shows the effects of positive and negative rake on finished gear teeth. Incorrect positive rake (A) increase the depth and decreases the pressure angle on the hob tooth. The resulting gear tooth is thick at the top and thin at the bottom. Incorrect negative rake (B) decreases the depth and increases the pressure angle. This results in a cutting drag and makes the gear tooth thin at the top and thick at the bottom.
A programmable algorithm is developed to separate out the effect of eccentricity (radial runout) from elemental gear inspection date, namely, profile and lead data. This algorithm can be coded in gear inspection software to detect the existence, the magnitude and the orientation of the eccentricity without making a separate runout check. A real example shows this algorithm produces good results.
We are all looking for ways to increase production without sacrificing quality. One of the most cost-effective ways is by improving the substrate material of your hob. Solid carbide hobs are widely used in many applications throughout the world. LMT-Fette was the first to demonstrate the use of solid carbide hobs in 1993 on modern high-speed carbide (HSC) hobbing machines. Since then the process of dry hobbing has been continuously improving through research and product testing. Dry hobbing is proving to be successful in the gear cutting industry as sales for dry hobbing machines have steadily been rising along with the dramatic increase in sales of solid carbide hobs.
Computers are everywhere. It's gotten so that it's hard to find an employee who isn't using one in the course of his or her day - whether he be CEO or salesman, engineer or machinist. Everywhere you look, you find the familiar neutral-colored boxes and bright glowing screens. And despite the gear industry's traditional reluctance to embrace new technology, more and moe of what you find on those screens are gears.
In 1993, M & M Precision Systems was awarded a three-year, partial grant from the Advanced Technology Program of the Department of Commerce's National Institute of Standards and Technology (NIST). Working with Pennsylvania State University, M&M embarked on a technology development project to advance gear measurement capabilities to levels of accuracy never before achieved.
Nondestructive examination (NDE) of ferrous and nonferrous materials has long proved an effective maintenance and anomaly characterization tool for many industries. Recent research has expanded its applicability to include the inspection of large, open gear drives. Difficulties inherent in other NDE methods make them time-consuming and labor-intensive. They also present the user with the environmental problem of the disposal of used oil. The eddy current method addresses these problems.
Back in the days when our great, great, great, etc., grandaddies were designing gears, one of the most common materials in use was wood. For fairly obvious reasons, we don't see too many wooden gears around anymore. But there are a few.
Designing and manufacturing gears requires the skills of a mathematician, the knowledge of an engineer and the experience of a precision machinist. For good measure, you might even include the are of a magician, because the formulas and calculations involved in gear manufacturing are so obscure and the processes so little known that only members of an elite cadre of professionals can perform them.
Standards are unlike gears themselves: mundane, but complex, ubiquitous and absolutely vital. Standards are a lingua franca, providing a common language with reference points for evaluating product reliability and performance for manufacturers and users. The standards development process provides a scientific forum for discussion of product design, materials and applications, which can lead to product improvement. Standards can also be a powerful marketing tool for either penetrating new markets or protecting established ones.
A major source of helicopter cabin noise (which has been measured at over 100 decibels sound pressure level) is the gear box. Reduction of this noise is a NASA and U.S. Army goal.
The type of lubricant and the method of applying it to the tooth flanks of large open gears is very important from the point of view of lubrication technology and maintenance. When selecting the type of lubricant and the application method, it is important to check whether it is possible to feed the required lubricant quantity to the load-carrying tooth flanks, This is necessary to avoid deficient lubrication, damage to the gear and operational malfunctions. It is important to determine the type of lubricant, which may be fluid or grease-like. The consistency of the lubricant will have a direct impact on the ability of the lubrication system to feed adequately the lubricant to the gear. The interactions between the common types of lubricant and the lubrication application methods for open gear drives are shown in Fig. 1.
Earlier this year, a relative of mine, Sidney Mandell, tragically passed away. I had the good fortune to serve with Sidney on the Board of Directors and the Executive Committee of the Machinery Dealers National Association (MDNA). Though he started before me, his MDNA career and mine overlapped for about 2 years. As I think back on the many things I learned form him, one of his favorite phrases keeps come to mind: "We walk in the footsteps of those who have gone before us."
Information is the name of the game in the 90s. We need more of it; we need it faster; and we need it in infinitely manipulatable and user-friendly form. In many cases, getting it that way is still something of a Holy Grail, somewhere off on the distant horizon. But thanks to computer technology, bit by byte, we're getting there.
Your Addendum team has come across a number of Good Ole Boys in its time; now we bring you something of even more interest - a Good Ole Gear Book. Mr. Robert Price, of Automation - Gears - Machinery, a gear consulting firm in Delanson, NY, shared with us a real find.
There are problems in dimensional measurement that should be simple to solve with standard measuring procedures, but aren't. In such cases, using accepted practices may result in errors of hundreds of microns without any warning that something is wrong.
Question: When we purchase our first CNC gear hobbing machine, what questions should we ask about the software? What do we need to know to correctly specify the system requirements?
It used to be that a shop with hustle and plenty of big, fast machines could thrive using a manual system. But no more. Today's economic environment requires more and more in the way of topnotch service and quick turnaround - which frequently means a completely integrated shop floor control system.
Gear design has long been a "black art." The gear shop's modern alchemists often have to solve problems with a combination of knowledge, experience and luck. In many cases, trial and error are the only effective way to design gears. While years of experience have produced standard gearsets that work well for most situations, today's requirements for quieter, more accurate and more durable gears often force manufacturers to look for alternative designs.
Arrow Gear Company of Downers Grove, IL, has implemented a computer system that fully integrates exchange between all of its computer applications. The ELIMS (Electronic Linkage of Information Management Systems) project has increased manufacturing productivity and reduced lead times.
You're already a veteran of the computer revolution. Only you and your controller know how much money you've spent and only your spouse knows how many sleepless nights you've had in the last ten years trying to carve out a place in the brave new world of computerized gear manufacturing. PC's, CNCs, CAD, CAM, DNC, SPC, CMM: You've got a whole bowl of alphabet soup out there on the shop floor. Overall these machines have lived up to their promises. Production time is down, quality is up. You have fewer scrapped parts and better, more efficient machine usage.
In some gear dynamic models, the effect of tooth flexibility is ignored when the model determines which pairs of teeth are in contact. Deflection of loaded teeth is not introduced until the equations of motion are solved. This means the zone of tooth contact and average tooth meshing stiffness are underestimated, and the individual tooth load is overstated, especially for heavily loaded gears.
This article compares the static transmission error and dynamic load of heavily loaded, low-contact-ratio spur gears when the effect of tooth flexibility has been considered and when it has been ignored. Neglecting the effect yields an underestimate of resonance speeds and an overestimate of the dynamic load.
The complete and accurate solution t the contact problem of three-dimensional gears has been, for the past several decades, one of the more sought after, albeit elusive goals in the engineering community. Even the arrival on the scene in the mid-seventies of finite element techniques failed to produce the solution to any but the most simple gear contact problems.
Could the tip chamfer that manufacturing people usually use on the tips of gear teeth be the cause of vibration in the gear set? The set in question is spur, of 2.25 DP, with 20 degrees pressure angle. The pinion has 14 teeth and the mating gear, 63 teeth. The pinion turns at 535 rpm maximum. Could a chamfer a little over 1/64" cause a vibration problem?
In this issue of Gear Technology, we are focusing on using computers to their greatest advantage in gear design and manufacturing. In a sense, that's old news. It's a cliche to suggest that computers make our work life easier and more productive. No company that wishes to remain competitive in today's global manufacturing environment can afford to be without computers in all their manifestations. We need them in the office; we need them next to our desks in place of drafting boards; we need them on the shop floor.
The aim of this article is to show a practical procedure for designing optimum helical gears. The optimization procedure is adapted to technical limitations, and it is focused on real-world cases. To emphasize the applicability of the procedure presented here, the most common optimization techniques are described. Afterwards, a description of some of the functions to be optimized is given, limiting parameters and restrictions are defined, and, finally, a graphic method is described.
Most gear cutting shops have shelves full of expensive tooling used in the past for cutting gears which are no longer in production. It is anticipated that these cutters will be used again in the future. While this may take place if the cutters are "standard," and the gears to be cut are "standard," most of the design work done today involves high pressure angle gears for strength, or designs for high contact ratio to reduce noise. The re-use of a cutter under these conditions requires a tedious mathematical analysis, which is no problem if a computer with the right software is available. This article describes a computerized graphical display which provides a quick analysis of the potential for the re-use of shaving cutters stored in a computer file.
Many CAD (Computer Aided Design) systems have been developed and implemented to produce a superior quality design and to increase the design productivity in the gear industry. In general, it is true that a major portion of design tasks can be performed by CAD systems currently available. However, they can only address the computational aspects of gear design that typically require decision-making as well. In most industrial gear design practices, the initial design is the critical task that significantly effects the final results. However, the decisions about estimating or changing gear size parameters must be made by a gear design expert.
One of our readers in England has asked for our help in locating published technical data and information on the design, manufacture, and inspection of camshaft gears. Although millions of these gears have been made and are in constant use, we are not aware of any formal material having been published. We would be pleased to hear from anyone who had knowledge of such information.
The availability of technical software has grown rapidly in the last few years because of the proliferation of personal computers. It is rare to find an organization doing technical work that does not have some type of computer. For gear designers and manufacturers, proper use of the computer can mean the difference between meeting the competition or falling behind in today's business world. The right answers the first time are essential if cost-effective design and fabrication are to be realized. The computer is capable of optimizing a design by methods that are too laborious to undertake using hard calculations. As speeds continue to climb and more power per pound is required from gear systems, it no longer is possible to design "on the safe side" by using larger service factors. At high rotational speeds a larger gear set may well have less capacity because of dynamic effects. The gear engineer of today must consider the entire gear box or even the entire rotating system as his or her domain.
This article discusses an application driven approach to the computer-aided sizing of spur gear teeth. The methodology is bases on the index of tooth loading and environment of application of the gear. It employs handbook knowledge and empirical information to facilitate the design process for a novice. Results show that the approach is in agreement with the textbook data. However, this technique requires less expert knowledge to arrive at the conclusion. The methodology has been successfully implemented as a gear tooth sizing module of a parallel axis gear drive expert system.
The art of gear hobbing has advanced dramatically since the development and introduction of unique machine and tool features such as no backlash, super rigidity, automatic loading of cutting tools, CNC controls, additional machine power and improved cutter materials and coatings. It is essential to utilize all these features to run the machine economically.
Computer programs have been developed to completely design spur and helical gear shaper cutters starting from the specifications of the gear to be cut and the type of gear shaper to be used. The programs generate the working drawing of the cutter and, through the use of a precision plotter, generate enlarge scaled layouts of the gear as produced by the cutter and any other layouts needed for its manufacture.
Helical gears can drive either nonparallel or parallel shafts. When these gears are used with nonparallel shafts, the contact is a point, and the design and manufacturing requirements are less critical than for gears driving parallel
shafts.
One of the current research
activities here at California State University at Fullerton is systematization of existing knowledge of design of planetary gear trains.
Much of the information in this article
has been extracted from an AGMA
Technical Paper, "What Single Flank
Testing Can Do For You", presented in
1984 by the author
Material losses and long production times are two areas of conventional spur and helical gear manufacturing in which improvements can be made. Metalforming processes have been considered for manufacturing spur and helical gears, but these are costly due to the development times necessary for each new part design. Through a project funded by the U.S. Army Tank - Automotive Command, Battelle's Columbus
Division has developed a technique for designing spur and helical gear forging and extrusion dies using computer aided
techniques.
History comes around full circle. It is interesting to talk to gear manufacturers who service the defense, aerospace, automotive and computer industries and find that their sales, production and backlogs reflect excellent and, in some cases, record breaking business.
With the publishing of various ISO draft standards relating to gear rating procedures, there has been much discussion in technical papers concerning the various load modification factors. One of the most basic of parameters affecting the
rating of gears, namely the endurance limit for either contact or bending stress, has not, however, attracted a great deal of attention.