Powder metal. To gear makers today, the phrase conjures images of low power applications in non-critical systems. As powder metal technology advances, as the materials increase in density and strength, such opinions are changing. It is an ongoing, evolutionary process and one that will continue for some time. According to Donald G. White, the executive director of the Metal Powder Industries Federation, in his State-of-the-P/M Industry - 1999 report. "The P/M world is changing rapidly and P/M needs to be recognized as a world-class process - national, continental and even human barriers and prejudices must be eliminated - we must join forces as a world process - unified in approach and goals."
If you think Y2K will mean the end of the world, forget it. General Vladimir Dvorkin recently said, "I'd like to apologize beforehand if I fail to realize someone's hopes for the Apocalypse." Te general was, of course, discussing Russian nuclear missiles, making the point that they are not going to launch or detonate when the calendar rolls over to January 1, 2000. General Dvorkin's American counterparts are similarly optimistic. While all that is a relief, it raises the question: will Y2K be as kind to the rest of society? And more specifically, will it be as kind to the gear industry? According to AGMA's president, Joe Franklin, the answer is a resounding "yes." According to Franklin, the AGMA Board considers Y2K a non-issue within an industry that is well ahead of others in its preparedness for January 1, 2000. But is it really? Does the gear industry understand the problem any better than other sectors of society? It's a relief to know that the nuclear bombs are not likely to fall within the first moments of the year 2000, but how about the computers and machines that keep the worldwide economy together?
Three years ago, coated gears seemed to be the perfect solution for the Micro Marine Corporation. The early designs for the gear drive of their MicroCAT human-powered boat used a combination of thin-film dry gear coatings with lubrication and wear-resistance properties. These coatings simplified their design, provided corrosion resistance, made the gear drive environmentally safe and eliminated the need for gear drive lubrication and maintenance. It was a success story in the making.
I must admit that after thumbing through the pages of this relatively compact volume (113 pages, 8.5 x 11 format), I read its three chapters(theory of gearing, geometry and technology, and biographical history) from rear to front. It will become obvious later in this discussion why I encourage most gear engineers to adopt this same reading sequence!
Gear Expo 99, AGMA's biennial showcase for the gear industry, has left the Rust Belt this year and landed in Music City U.S.A., Nashville, Tennessee. The event, with exhibitors from around the globe showing off the latest in gear manufacturing as well as metal working processes, will be held at the Nashville Convention Center, October 24-27, 1999. According to Kurt Medert, AGMA vice president and Gear Expo show manager, "In choosing Nashville, AGMA;s Trade Show Advisory Council found a city that is an excellent trade show site. It has the right mix of convention center, nearby hotels, and a clean downtown area with entertainment readily available for the exhibitors and visitors alike. Nashville is in the heart of southern industry, which we see as a focus of growth for the gear industry and its customers."
The cutting tool industry has undergone some serious changes in the last couple of years in both technology and the way the industry does business. The emerging technology today, as well as for the foreseeable future, is dry cutting, especially in high volume production settings. Wet cutting continues to be as popular as ever with lubrication advances making it more economical and environmentally friendly. There has also developed a process called "near dry cutting." this process offers many of the benefits of fluids while eliminating many of hte associated problems.
In his Handbook of Gear Design (Ref.1), Dudley states (or understates): "The best gear people around the world are now coming to realize that metallurgical quality is just as important as geometric quality." Geometric accuracy without metallurgical integrity in any highly stressed gear or shaft would only result in wasted effort for all concerned - the gear designer, the manufacturer, and the customer - as the component's life cycle would be prematurely cut short. A carburized automotive gear or shaft with the wrong surface hardness, case depth or core hardness may not even complete its basic warranty period before failing totally at considerable expense and loss of prestige for the producer and the customer. The unexpected early failure of a large industrial gear or shaft in a coal mine or mill could result in lost production and income while the machine is down since replacement components may not be readily available. Fortunately, this scenario is not common. Most reputable gear and shaft manufacturers around the world would never neglect the metallurgical quality of their products.
Air compressors are a good example of industrial machinery with components that rotate at very high speeds, up to 80,000 rpm. They are subject to very high rotational forces and often variable loads. Strong, high-precision gears for the power transmission trains that drive the impellers are critical components of machinery operating under such conditions.
In 1927 the first precursor of IMTS was held in Cleveland. Back then, lasers, robots and computer controls were just science fiction. At IMTS 98 they will fill nearly every last corner of the recently expended McCormick Place.