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Milling

INDUSTRY NEWS | 2025-02-26

Index Corporation Announces Reorganization and Team Additions

Index Corporation has announced that Michael Huggett will succeed Cris Taylor as the company’s President & CEO. Mr. Huggett will assume leadership of the company during a transition period in April 2025, concluding with Mr. Taylor’s retirement at the end of that month. Index has also announced a restructuring of its sales team that includes the addition of three new members and reorganization of its territories. Bryan Young has joined the company as National Sales Manager, while John Kemezis and Jason Shorette have joined as Regional Sales Representatives.

EVENT | 2024-05-28

Okuma and Emuge-Franken Multitasking Event

Emuge-Franken USA is teaming up with Okuma America Corporation to present and demonstrate Multitasking Machining Innovations for complex turbine components on June 13th, 2024, from 9:00 a.m. – 3:00 p.m. at Okuma America Corporation located at 11900 Westhall Drive in Charlotte, North Carolina. This complimentary Multitasking Event is designed for manufacturing engineers.

PRODUCT NEWS | 2024-04-09

Mitsubishi Electric Automation Provides Machine Tending Solution for TL Aerotek

TL Aerotek, a small job milling shop customer, experienced a large influx of orders. To keep up with demand, they sought a solution that would alleviate labor uncertainty and help to grow the business. TL Aerotek turned to their long-time supplier of milling machines for support, Expand Machinery. 

PRODUCT NEWS | 2024-03-18

Introducing CoroMill MS60

Sandvik Coromant presents the latest addition to its family of milling tools: CoroMill MS60. The tool is tailored for 90-degree shoulder milling operations in steel and cast iron, but versatile enough to extend its competence across areas such as face milling and various ramping applications.

INDUSTRY NEWS | 2023-10-12

PTG Holroyd Wins Siemens' Global Award for Digital Transformation at EMO Hannover

EMO Hannover 2023 didn’t simply provide PTG Holroyd with a platform to showcase its industry-leading helical rotor and gear milling and grinding machines to a global audience. The UK-based machine tool manufacturer was presented with Siemens’ Digital Transformer award during the event.

VIDEO | 2023-09-25

Inside the DMG Mori Portal Series

Automobile manufacturers can develop ever more sophisticated car body molds because they can rely on 5-axis portal machines as the backbone of automotive tool and die making. The aerospace industry achieves unprecedented part quality thanks to full technology integration of milling, turning and grinding, ensuring maximum passenger safety. Thanks to 5-axis technology in large format, portal machines ensure that hydroelectric power can be converted into energy. Mechanical engineering also benefits worldwide from portal machines from Pfronten, which repeatedly demonstrate their performance in demanding machining operations such as gear production. DMG Mori has more than 1,400 Portal machines installed worldwide.

PRODUCT NEWS | 2023-09-15

GMTA Offers Profilator 300-V with Linear Drives to North American Market

German Machine Tools of America (GMTA) is now selling Profilator 300-V with linear drives in the North American market.
This modular machine platform used to cut gears, is equipped with one or two workpiece spindles in a compact design. It offers maximum flexibility due to modular design and is individually configurable for various machining processes (i.e. Scudding, hobbing, cycloidal milling, pointing, chamfering and deburring). State-of-the-art linear drives in the x and y axis, as well as a torque drive in the a axis offers high machine dynamics for short cycle times and maximum accuracy/low costs. High machine rigidity is available for Hard Scudding of inner and outer diameters. 

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INDUSTRY NEWS | 2023-04-28

Titanium Machining—Special Materials for Complete Machining

Heavy duty cutting places particular requirements on the machine and working processes. If this involves a material such as titanium, which is particularly hard to cut, specific know-how is necessary to deal with these requirements. Thanks to its expertise, WFL Millturn Technologies GmbH & Co. KG impresses in this field with a machining solution for aircraft landing gear.

INDUSTRY NEWS | 2023-02-06

State of the Gear Industry Perspectives: Helios Gear Products

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 fifth installment online is an interview with Adam Gimpert, president, Helios Gear Products.

INDUSTRY NEWS | 2022-10-24

New CoroMill MF80 for high-performance face and shoulder milling

Global metal-cutting leader Sandvik Coromant is expanding its milling offering with the new CoroMill MF80 for automotive milling applications in ISO K and ISO P materials in close to 90-degree operations with fixture constraints.

PRODUCT NEWS | 2022-10-12

Seco Tools Provides Quick-Change Milling Head System

To provide manufacturers versatility and high value, Seco has launched its new X-Head quick-change replaceable milling head system. With the system, users can quickly and easily change between various solid carbide milling geometries and types to optimize milling operations while reducing manufacturing costs and tooling inventories.

INDUSTRY NEWS | 2022-08-30

ANCA Launches the MX7 Ultra Machine Range of Cutting Tools at IMTS 2022

The new ANCA MX7 ULTRA can manufacture large volumes of precision endmills and other cutting tools. The minute size of a micron is beyond the human eye, but by moving from micrometers to nanometers, ANCA will offer the highest accuracy and quality in a cutting tool in the market. 

INDUSTRY NEWS | 2022-08-16

WFL Offers Latest Multifunctional Machine Technology at IMTS 2022

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. 

INDUSTRY NEWS | 2022-07-29

MC Machinery Systems Announces Promotions

MC Machinery Systems recently announced the promotions of Joe Cisneroz, Dave Kloos and Doug Conroy as well as the addition of Alexander Wright. 

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INDUSTRY NEWS | 2022-07-26

MC Machinery Introduces Machining Technology at IMTS 2022

MC Machinery will showcase its latest EDM and precision milling technology, including wire and sinker EDMs, machining centers and automation during IMTS 2022.

INDUSTRY NEWS | 2022-06-22

Index Launches Next Generation of G220 Turn-Mill Center

Index has announced the release of next generation of its G220 turn-mill center. Incorporating the design principles introduced via the larger G320, G420 and G520 machines, the new G220 provides high flexibility to produce complex, small-to-medium-sized parts in a single setup.

INDUSTRY NEWS | 2022-06-21

Gleason Corporation Announces the Passing of James S. Gleason

It is with great sadness Gleason Corporation announces the passing of James S. Gleason, a Gleason board member and former chairman and CEO of the company who died on June 17th at the age of 88 years old.  Jim, a great grandson of the company’s founder William Gleason, contributed to the company in various roles, continuing to serve as a director on the board up until his death. 

INDUSTRY NEWS | 2022-06-13

Universal Robots USA Offers E-Book on Cobots

Collaborative robots can increase output and improve quality in nearly any production environment. UR cobots can be deployed quickly, with fast ROI, typically within 12 months. Universal Robots USA has released an e-book on how cobots can assist on the shop floor in the following areas: 

INDUSTRY NEWS | 2022-06-03

Mazak Highlights Manufacturing Solutions at IMTS 2022

At IMTS 2022 in Booth #338300, Mazak will show manufacturers how they can move their manufacturing operations forward with the company's latest innovations. Five pavilions will showcase solutions for job shops, advanced machining and high-production workflows.

INDUSTRY NEWS | 2022-05-31

EMCO Expands Machining Capabilities in Italy

EMCO caters for customers from industries which are as versatile as the company's range of products. Traditional small and medium-sized companies have been an integral part of EMCO's customer base for many years.

PRODUCT NEWS | 2022-05-26

Metal Cutting Robots

Kadia has been designing deburring robot cells based on 6-axis industrial robots for many years. In the meantime, a new trend is now emerging, solutions with an even higher value-added component, i.e., with general machining processes such as milling, drilling or thread cutting. The robot is thus no longer just part of a deburring machine.

INDUSTRY NEWS | 2022-05-24

Chiron Presents Machining Innovations for the Future

The Chiron Group Open House in Tuttlingen, Germany welcomed more than 1,200 expert visitors from around the world May 11-13, offering new ideas and to improve their manufacturing practice – in the Chiron spirit of “Performance meets Precision.”

INDUSTRY NEWS | 2021-12-14

Modified Crowning with Klingelnberg

Klingelnberg examines how engine management in electrically driven cars requires a very different specification of the driveline and the gearbox.
INDUSTRY NEWS | 2021-12-06

Bredel Achieves Flexibility with WFL Turning-Milling Machine

Bredel in Delden, manufacturer of industrial hose pumps, has invested in a M65-G Millturn turning-milling centre from WFL. The machine to...
INDUSTRY NEWS | 2021-11-15

Walter Introduces New Face Milling Cutter

Walter has introduced the Xtra·tec XT M5009 face milling cutter for face milling, roughing, and rough finishing with wiper inserts...
INDUSTRY NEWS | 2021-09-28

Ingersoll Introduces NuMaxHF Line of Milling Tools

The NuMaxHF line of new hi-feed milling tools from Ingersoll Cutting Tools offers extreme ramping capabilities versus traditional hi-feed...
INDUSTRY NEWS | 2021-03-11

Big Kaiser Adds Chip Blower for use with Hydraulic and Milling Chucks

Big Kaiser Precision Tooling has updated its offering of Chip Blowers, which are designed to make removing chips and coolant from parts a...
INDUSTRY NEWS | 2021-02-22

Fatigue Strength and Service Calculation of Gears

Bevel gear design is well-established. Flank geometry optimization is used worldwide to ensure satisfactory low-noise emis...

INDUSTRY NEWS | 2020-11-19

C-B Gear & Machine Expands Capability with 5-Axis Milling

C-B Gear & Machine has expanded its precision milling capability with the addition of a new DMG MORI DMU 210P2 5-axis milling center....
FEATURE ARTICLES | 2020-11-01

HMC and Liebherr Collaborate on Large Scale Gear Production Project

A visit to the HMC Gears plant in Indiana kicked off an extensive project which resulted in the creation of a unique solution for exceptional demands: With the LC 4000, Liebherr forges new paths in large-scale gear cutting production and unites diverse machining methods in one highly efficient machine for the American gear specialist.
GEAR TALK WITH CHUCK | 2020-09-16

Learning the Ropes

Ever wonder about the origin of common phrases? As the son of a sailor, I have always enjoyed maritime history and nautical fiction, although some ...
INDUSTRY NEWS | 2020-08-24

Big Kaiser Adds Noventa from Sphinx to Milling Cutter Lineup

Big Kaiser Precision Tooling introduces the Noventa from Sphinx, the newest addition to its milling cutter lineup. The Noventa is ideal f...
GEAR TALK WITH CHUCK | 2020-08-01

IMTS Future Tech

The Digital Manufacturing Revolution Evolves in 2020 IMTS will offer two comprehensive digital programs, IMTS Network and IMTS Sp...

INDUSTRY NEWS | 2020-07-31

GF Machining Solutions Offers Automated Machine Calibration for Milling Machines

Changes in ambient temperature or working environment and machining parts over long periods of time all impact a milling machine's ge...
INDUSTRY NEWS | 2020-06-17

Hoffmann Group Taps WFL Millturn to Test and Optimize Tools

Pushed to the Maximum

With over 4,000 employees and an extensive range of tools, operating equipment and personal protec...
TECHNICAL ARTICLES | 2020-05-01

Prototyping on Bevel Gear Cutting and Grinding Machines

Why Prototyping with End-mills on Bevel Gear Machines? Manufacturing of spiral bevel and hypoid gears can be conducted in several ways.
INDUSTRY NEWS | 2020-04-29

Seco Cutters Enable Smooth Disc Milling Operation

To address the difficulties manufacturers face when performing disc milling operations in hard-to-machine materials, Seco Tools has annou...
INDUSTRY NEWS | 2020-01-24

Kyocera Develops New Generation of High-Performance Milling Cutters

Kyocera Corporation announced its new MEV series of efficient, multi-functional milling cutters for metal machining applications. The n...
TECHNICAL ARTICLES | 2020-01-01

CNC Manufacturing of Circular Faced Cylindrical Gears

Spur cylindrical gears are usually cut using a hob and therefore present an essentially straight face to which crowning can be added to prevent edge contact. Rather than using a rack or hob, it is possible to cut cylindrical gears with a face mill cutter. In the following presentation, these gears are termed "spurved," i.e. — a contraction of "spur" and "curved."
TECHNICAL ARTICLES | 2019-11-01

Reverse Cutter Hand for Face Milling and Face Hobbing

Is a left-hand cutter required for a left-hand face mill part?
INDUSTRY NEWS | 2019-10-29

Emuge Expands Slim Line Chucks for 5-Axis Milling Versatility

Emuge Corp. has expanded its line of FPC Milling/ Drilling Chucks products to include Slim Line models that are designed to enhance 5-Axi...
INDUSTRY NEWS | 2019-09-26

TCI Precision Metals Adds Duplex Milling Technology

TCI Precision Metals has announced the installation of its newest high tech milling machine. The new Amada, THV800 is the latest in preci...
INDUSTRY NEWS | 2019-06-20

Walter Solid Carbide Milling Cutters Provide High Metal Removal Rates

Walter has introduced the MC319/MC320 Advance Line of solid carbide milling cutters that have been specially engineered to meet the needs...
GEAR TALK WITH CHUCK | 2019-06-18

Claude Gosselin: Gears — Why Not?

When I graduated as a mechanical engineer in 1978, I landed a job in the “cold section” at Pratt & Whitney Canada (PWC) in Montreal. In those d...
GEAR TALK WITH CHUCK | 2019-06-11

Rob Swiss — The Accidental Engineer

Another young man discovers you need not be an expert machinist to succeed as a gear engineer. Spoiler alert: never tangle with a grinding wheel; they are undefeated in all time.
TECHNICAL ARTICLES | 2019-05-01

Generative Gear Milling

This paper outlines the basic principles of involute gear generation by using a milling cutter; the machine and cutting tool requirements; similarities and differences with other gear generative methods; the cutting strategy; and setup adjustments options. It also discusses the applications that would benefit the most: for coarse-pitch gears the generative gear milling technologies offer improved efficiency, expanded machine pitch capacity, decreased cutter cost, and a possibility for reducing the number of machining operations.
INDUSTRY NEWS | 2019-04-30

Forest City Gear Launches Advanced Turning and Milling Facility for Gear Blank Production

Forest City Gear has expanded its turning and milling operations with a state-of-the-art facility designed to greatly improve lead times ...
GEAR TALK WITH CHUCK | 2019-04-16

Joe Arvin — My Story

Today’s origin story is by one of the true “good guys” in our trade. I first met Joe in 1989 when I was job hunting. He could tell I was in a b...
GEAR TALK WITH CHUCK | 2019-02-28

Gone but Not Forgotten

Continuing our discussion of veteran machine tools, it occurs to me that many of our younger readers may not be aware that the United States was on...
GEAR TALK WITH CHUCK | 2019-01-30

From Co-op to Vice President: Octave A. LaBath

I was attending the University of Cincinnati in the college of engineering. After my freshman year in 1960, I started my co-op job with the Cincinn...
TECHNICAL ARTICLES | 2019-01-01

CNC Milling of Straight and Spiral Bevel Gears

Contrary to what appears to be popular belief, 5-axis CNC gear manufacturing is not limited to milling with end mill, ball mill or CoSIMT (Conical Side Milling Tool — it is the generic form of the Sandvik InvoMill and Gleason UpGear tools.) tools, where throughput is too low to prevent production at any significant level. Straight and spiral bevel gear manufacturing on 5-axis CNC machines using face mill cutters provides essentially the same throughput as conventional gear cutting machines — with added benefits.
GEAR TALK WITH CHUCK | 2018-12-04

Dealing with Obsolescence

Emerging technology gets lots of coverage in all forms of media; obsolete technology is still the backbone of our economy. Self-driving vehicles ex...
TECHNICAL ARTICLES | 2018-11-01

PentacMono-RT: High-Performance Face Milling Cutter Heads

The theory behind the latest bevel gear cutting tools is explained in detail.
INDUSTRY NEWS | 2018-10-17

Kennametal Releases Latest Helical Milling Cutter

Kennametal recently released its newest helical milling cutter, the Harvi Ultra 8X.Using a 95 mm (3.74 in.) axial depth of cut, 20 mm (...
GEAR TALK WITH CHUCK | 2018-09-27

Acceptable Fixes

You do not always have to say “no” when confronted with non-conforming parts. Here are a few “fixes” I have been comfortable authorizing:

FEATURE ARTICLES | 2018-09-01

The Evolution of Gear Chamfering

The latest technological solutions help keep chamfering and deburring operations in-line -- often without increasing cycle times.
INDUSTRY NEWS | 2018-08-13

International Gear Conference 2018

Lyon, France. Mechanical transmission components such as gears, rolling element bearings, CVTs, belts, chains, etc. are present in every industrial...
GEAR TALK WITH CHUCK | 2018-02-01

Understanding Spur Gears

Spur gears have been around “forever.” That ancient astronomical device recovered from the Mediterranean Sea a few years ago shows the antiquity an...
INDUSTRY NEWS | 2018-01-12

Sandvik Coromant InvoMilling CAD/CAM Software Offers Additional Five-Axis Functionality

Cutting tool and tooling system specialist Sandvik Coromant has extended the functionality of its InvoMilling software. Th...
PUBLISHER'S PAGE | 2018-01-01

We'd Grow Faster If We Could

It's probably no surprise to anyone that the majority of the gear industry had a pretty good year in 2017, and that most gear manufacturers are expecting a pretty good 2018 as well. After all, most major economic indicators - including the ones that focus on the manufacturing sector - have been positive for some time.
INDUSTRY NEWS | 2017-12-27

Holroyd 8EX Rotor Milling Machine and CS700E Tool Management Center Ordered by Chinese Air Compressor Manufacturer

One of China's leading manufacturers of air compressors has once again demonstrated its confidence in the ultra-precise technologies ...
GEAR TALK WITH CHUCK | 2017-12-12

Engineering Safety (Part One)

Watching the movie Deepwater Horizon got me thinking about current attitudes on workplace safety. (Full disclosure — I am a bit of a cr...
INDUSTRY NEWS | 2017-10-03

Sandvik Coromant CoroMill 745 Face Milling Cutter Provides Higher Metal Removal Rates for Roughing and Semi-Finishing Milling Operations

Cutting tool and tooling system specialist Sandvik Coromant has unveiled a new, high-feed version of the CoroMill 745 face mill...
GEAR TALK WITH CHUCK | 2017-09-21

Who Do You Think You Are?

My last posting recommended preparing an “elevator pitch” ahead of attending the AGMA Fall Technical Meeting and Gear Expo. I have gone through thi...
INDUSTRY NEWS | 2017-06-13

Mastercam 2018 Focuses on Efficiency and Speed

Mastercam 2018 was recently introduced at EASTEC where attendees were impressed with the tools the software has available to get parts off...
GEAR TALK WITH CHUCK | 2017-05-19

Exploring New Methods

I have been following developments on gear making in general-purpose CNC machines with great interest. The advent of affordable gear grinding seems...
INDUSTRY NEWS | 2017-05-04

Walter MC232 Perform Milling Cutters Provide Universal Applicability for Milling Operations

Walter has added to its range of solid carbide milling cutters with the introduction of its MC232 Perform product line. These three versa...
GEAR TALK WITH CHUCK | 2017-04-13

Fundamentals of Maintenance

Modern cars and trucks are wonderfully reliable and durable. As much as I love old cars I cannot cleanse my memory of the heartbreaking behavior th...
INDUSTRY NEWS | 2017-03-13

Sandvik Coromant Silent Tools Milling Adapters Designed to Improve Damping Characteristics

The latest Silent Tools milling adapters from cutting tool and tooling systems specialist Sandvik Coromant are designed to offer improved...
FEATURE ARTICLES | 2017-03-01

Message Received

Big Data Expands Process Capabilities for Multi-Axis Machining.
FEATURE ARTICLES | 2017-03-01

5-Axis Gear Manufacturing Gets Practical

Exciting new machine, cutting tool and software technologies are compelling many manufacturers to take a fresh look at producing their larger gears on machining centers. They're faster than ever, more flexible, easy to operate, highly affordable - and for any type of gear.
TECHNICAL ARTICLES | 2017-03-01

Performance of Gears Manufactured by 5-Axis Milling

Free form milling of gears becomes more and more important as a flexible machining process for gears. Reasons for that are high degrees of freedom as the usage of universal tool geometry and machine tools is possible. This allows flexible machining of various gear types and sizes with one manufacturing system. This paper deals with manufacturing, quality and performance of gears made by free form milling. The focus is set on specific process properties of the parts. The potential of free form milling is investigated in cutting tests of a common standard gear. The component properties are analyzed and flank load-carrying capacity of the gears is derived by running trials on back-to-back test benches. Hereby the characteristics of gears made by free form milling and capability in comparison with conventionally manufactured gears will be shown.
INDUSTRY NEWS | 2017-03-01

Industry News

Educational initiatives, company news, acquisitions and people in the industry are all featured this issue.
INDUSTRY NEWS | 2017-02-24

Controx-Neuhauser Saw Blades and Side Milling Cutters On Display at PMTS

Controx-Neuhauser is presenting a full line of standard saw blades and side chip clearance saws suitable for a wide range of precision cu...
INDUSTRY NEWS | 2017-02-16

Mitsui Seiki PJ812 Offers High-Precision Milling for Components with Critical Tolerances

The new Mitsui Seiki PJ812 Precision Profile Center is a three-axis CNC vertical jig mill engineered to perform high-precision contour ma...
INDUSTRY NEWS | 2017-01-25

Heimatec Angle Heads Offers Heavy-Duty Industries Standard or Custom Milling, Drilling and Tapping Solutions

Heimatec announced the immediate availability of its newest development, a line of standard and custom angle heads, available in all popu...
INDUSTRY NEWS | 2017-01-03

Mazak Integrex i-200S AM Offers All-in-One Milling and Additive Manufacturing Capabilities

Mazak continues to fortify its industry leadership in hybrid multi-tasking machine technology with the introduction of its new Integrex i...
ASK THE EXPERT | 2017-01-01

Best Tooling for Hard Milling a Gear Tooth on 5-Axis Machining Center

What is the best tooling to use when hard milling a gear tooth on a 5-axis machining center? And what makes it the best? We have just bought a DMG Mori mono-block and are not getting the finishes at the cycle times we require.
INDUSTRY NEWS | 2016-12-19

Sandvik Coromant GC1130 Steel Milling Grade Operates in Both Wet and Dry Conditions

Cutting tool and tooling systems specialist Sandvik Coromant has made its high performance steel milling grade, GC1130, available for use...
TECHNICAL ARTICLES | 2016-11-01

Optimal Flank Forms for Large Bevel Gears

At first sight the appearance of 5-axis milling for bevel gears opens new possibilities in flank form design. Since in comparison to existing machining methods applying cutter heads no kinematic restrictions exist for 5-axis milling technology, any flank form can be machined. Nevertheless the basic requirements for bevel gears did not change. Specifications and functional requirements like load carrying capacity and running behavior are still increasing demands for design and manufacturing. This paper describes the demands for gear design and gives an overview about different design principles in the context of the surrounding periphery of the gear set.
INDUSTRY NEWS | 2016-10-20

Walter MC341 Supreme Carbide Milling Cutter Designed for Machining Steel and Stainless Steel

The new MC341 Supreme carbide shoulder/slot milling cutter from Walter is specially designed for extended tool life when machining steel ...
GEAR TALK WITH CHUCK | 2016-10-20

Non-Traditional Manufacturing

While 3-D printing looks for its place in the manufacturing world, other non-traditional methods are finding their way into our gear shops. Some, s...
INDUSTRY NEWS | 2016-09-19

Holroyd Tool Management Center Improves Accuracy and Repeatability of Milling Large Helical Rotors

A newly developed ‘large diameter' CNC cutter grinding machine from Holroyd Precision Ltd is designed to bring considerable adv...
FEATURE ARTICLES | 2016-09-01

Innovating Against the Tide

During a year with a strong dollar, tanked oil prices and a number of soft markets that just aren't buying, one might expect spline manufacturers to be experiencing the same tumult everyone else is. But when I got a chance to speak with some of the suppliers to spline manufacturers at IMTS about how business is going, many of the manufacturing industry's recent woes never came up, and instead were replaced by a shrug and an "eh, business is doing pretty well."
TECHNICAL ARTICLES | 2016-09-01

A Proposed Pre-Finish Cylindrical Gear Quality Standard

This proposed standard would not make any recommendations regarding the required quality for any application. The intent is to establish standard pre-finish quality classes for typical finishing operations, which only include the inspection elements that are important to properly evaluate pre-finish gear quality as it applies to the finishing operation. It would be the responsibility of the manufacturing/process engineer, quality engineer, or other responsible individual to establish the required pre-finish quality class for their application.
GEAR TALK WITH CHUCK | 2016-08-02

Standing on the Shoulders of Giants

  Our Facebook page recently displayed some great vintage photos of the old Mesta Machine shop. Back when American firms built the biggest ...
INDUSTRY NEWS | 2016-07-20

Covering All Angles

Klingelnberg Hosts 6th WZL Gear Conference in the USA 2016  Matthew Jaster, Senior Editor ...
INDUSTRY NEWS | 2016-07-15

Walter M4000 Family Helical Milling Cutters Expanded to Include Three New Models

Walter has announced the addition of the M4256, M4257 and M4258 high-performance helical milling cutters to its M4000 family. The M4000 p...
PUBLISHER'S PAGE | 2016-07-01

Life in High Gear

Most books related to the gear industry are more about the business side or the technical aspects of what we do.
INDUSTRY NEWS | 2016-06-08

EMCO Umill 1800 5-Axis Milling-Turning Machine

The Umill 1800 from Mecof, part of EMCO Group, offers milling and turning solutions designed to meet the needs of mold makers and aerospa...
TECHNICAL ARTICLES | 2016-06-01

Worm Gear Efficiency Estimation and Optimization

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
TECHNICAL ARTICLES | 2016-06-01

Bevel Gear Cutting Methods

THE FINAL CHAPTER This is the last in the series of chapters excerpted from Dr. Hermann J. Stadtfeld's Gleason Bevel Gear Technology - a book written for specialists in planning, engineering, gear design and manufacturing. The work also addresses the technical information needs of researchers, scientists and students who deal with the theory and practice of bevel gears and other angular gear systems. While all of the above groups are of course of invaluable importance to the gear industry, it is surely the students who hold the key to its future. And with that knowledge it is reassuring to hear from Dr. Stadtfeld of the enthusiastic response he has received from younger readers of these chapter installments.
INDUSTRY NEWS | 2016-05-16

Sandvik CoroMill 745 Offers Multi-Edge Milling Concept

Offering high productivity and a low cost per edge, the CoroMill 745 has a double-sided, multi-edge design that is ideal for large b...
INDUSTRY NEWS | 2016-05-04

Holroyd EX Rotor Milling Machines Rough Mill and Finish Machine Stainless Steel Rotors

A little over two years after building one of the world's largest rotor milling machines - an EX Series ‘8EX' model - for a...
INDUSTRY NEWS | 2016-04-04

Big Kaiser Mega Perfect Grip Milling Chuck Designed to Eliminate End Mill Pullout

Big Kaiser introduces the Mega Perfect Grip from Big Daishowa, a simple to handle, heavy-duty milling chuck for heat resistant super allo...
INDUSTRY NEWS | 2016-03-18

Sumitomo DFC Double-Side 90° Milling Cutter Offers High Wear Resistance, Precision and Efficiency

New from Sumitomo Electric Carbide Inc., the DFC Double-Sided 90º Milling Cutter is engineered for exceptional precision and efficie...
INDUSTRY NEWS | 2016-03-04

Emuge Appoints Dan Doiron to Project Manager of Milling

Emuge Corp. has announced the appointment of Mr. Dan Doiron to the position of Project Manager, Milling. In his new position Doiron will ...
TECHNICAL ARTICLES | 2016-03-01

Practical Gear Characteristics: Process Characteristics of the Most Popular Cutting Methods

The cutting process consists of either a roll only (only generating motion), a plunge only or a combination of plunging and rolling. The material removal and flank forming due to a pure generating motion is demonstrated in the simplified sketch in Figure 1 in four steps. In the start roll position (step 1), the cutter profile has not yet contacted the work. A rotation of the work around its axis (indicated by the rotation arrow) is coupled with a rotation of the cutter around the axis of the generating gear (indicated by the vertical arrow) and initiates a generating motion between the not-yet-existing tooth slot of the work and the cutter head (which symbolizes one tooth of the generating gear).
ASK THE EXPERT | 2016-03-01

Hard-Finishing Spiral Bevel Gears

Could you explain to me the difference between spiral bevel gear process face hobbing-lapping, face milling-grinding and Klingelnberg HPG? Which one is better for noise, load capacity and quality?
INDUSTRY NEWS | 2016-02-05

Pferd Cast Cut Carbide Burs Feature High Stock Removal Rate, Smooth Milling Action

Pferd Inc. has introduced Cast Cut, a new line of high-performance carbide burs specially designed for work on cast iron. They are charac...
INDUSTRY NEWS | 2016-01-18

Seco PCD05 and PCD20 Milling Insert Grades Designed for Use with Turbo 10 Cutters

Seco has introduced two new PCD-tipped milling insert grades – PCD05 and PCD20 – for use with Turbo 10 cutters. Suited to aer...
INDUSTRY NEWS | 2016-01-08

Walter Milling Grades Utilize Tiger-Tec Silver Technology

Walter has introduced the WKK25S, WSM45X and WNN15, a trio of new milling grades that deliver an array of benefits to the user, thanks to...
PRODUCT NEWS | 2015-09-01

Product News

News about New Products
TECHNICAL ARTICLES | 2015-09-01

Gear Tooth Surface Roughness of Helical Gears Manufactured by a Form Milling Cutter

Manufacturing involute gears using form grinding or form milling wheels are beneficial to hobs in some special cases, such as small scale production and, the obvious, manufacture of internal gears. To manufacture involute gears correctly the form wheel must be purpose-designed, and in this paper the geometry of the form wheel is determined through inverse calculation. A mathematical model is presented where it is possible to determine the machined gear tooth surface in three dimensions, manufactured by this tool, taking the finite number of cutting edges into account. The model is validated by comparing calculated results with the observed results of a gear manufactured by an indexable insert milling cutter.
TECHNICAL ARTICLES | 2015-07-01

I Like Big Gears and I Cannot Lie!

Many years ago, when asked how the five-meter gear was checked, the quality manager responded, “When they’re that big, they’re never bad!” That may have been the attitude and practice in the past, but it no longer serves the manufacturer nor the customer. Requirements have been evolving steadily, requiring gears to perform better and last longer.
TECHNICAL ARTICLES | 2015-06-01

An Approach to Pairing Bevel Gears from Conventional Cutting Machine with Gears Produced on 5-Axis Milling Machine

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.
PUBLISHER'S PAGE | 2015-06-01

Good Morning, Class

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.
GEAR TALK WITH CHUCK | 2015-05-28

Formula 1 Gearbox Designs

As mentioned in my last blog, Formula 1 gearboxes are now highly integrated into the overall car design. The days of a “spec” transmission from a t...
GEAR TALK WITH CHUCK | 2015-04-21

Play Through, Old Friend

One of the consequences of growing older is saying good bye to friends you have made along the way. Word reached me this week that one of the best ...
GEAR TALK WITH CHUCK | 2015-04-09

How Much is Too Much?

My inner curmudgeon got loose in the last blog and I want to assure you that I, too, love big horsepower. My concern is that it be applied safely. ...
INDUSTRY NEWS | 2015-03-09

Sandvik Introduces New CoroMill QD Groove Milling Concept

The main challenge in groove milling is often chip evacuation. Chip issues can harm production efficiency, lower component quality or cau...
TECHNICAL ARTICLES | 2015-01-01

Quality and Surface of Gears Manufactured by Free-Form Milling with Standard Tools

The recently available capability for the free-form milling of gears of various gear types and sizes — all within one manufacturing system — is becoming increasingly recognized as a flexible machining process for gears.
GEAR TALK WITH CHUCK | 2014-12-04

Overcoming Adversity

[starbox] My last blog concerned project management and the problems of staying on schedule. I thought it only fair to pass on some techniques I...
GEAR TALK WITH CHUCK | 2014-11-11

The War to End All Wars

[starbox] As the son of a World War II sailor, I was raised with an honest respect for our nation’s veterans. The massive size of WW II and its ...
FEATURE ARTICLES | 2014-11-01

Making it in Mobile

"If it's broken, bring it on in." That's the advice offered by Roy Parker, president and owner of Jones Welding Company Inc.
INDUSTRY NEWS | 2014-09-15

Sandvik Introduces InvoMilling 1.0 During IMTS

Sandvik Coromant introduced InvoMilling 1.0 during IMTS in Chicago. The InvoMilling solution was released as software supported by dedica...
GEAR TALK WITH CHUCK | 2014-09-09

Have You Been to the Circus Yet?

[starbox] As mentioned before in this space, the bi-annual International Machine Tool Show (IMTS) is back in Chicago (September 8 – 3th). I’ll b...
INDUSTRY NEWS | 2014-05-01

Industry News

The complete Industry News section from the May 2014 issue of Gear Technology.
GEAR TALK WITH CHUCK | 2014-04-24

Working Dinosaurs

[starbox] Reflecting upon “transformative technology,” I remember the sadness I felt at the Cincinnati Gear Company auction when a group of pris...
GEAR TALK WITH CHUCK | 2014-04-17

More Adventures in Modifying Machines

[starbox] In my last posting I wrote about some of the projects I have been involved with to squeeze a bigger part in an existing machine. Most ...
GEAR TALK WITH CHUCK | 2014-04-15

If the Shoe Doesn’t Fit …

[starbox] Blogging about emerging 3-D printing technology reminded me of occasions when it was necessary to “stretch the envelope” to get things...
GEAR TALK WITH CHUCK | 2014-04-10

Necessity is the Mother of Invention

[starbox] My last post may have been too hard on the emerging 3-D printing technology. We’ve always celebrated inventors in this country and per...
GEAR TALK WITH CHUCK | 2014-04-08

A Tool Looking for a Task?

[starbox] I have been hearing a lot about 3-D printing and how it will revolutionize manufacturing in the United States. Millions are slated to ...
INDUSTRY NEWS | 2014-03-06

PTG Holroyd Produces Large Helical Profile Milling Machine

Holroyd manufactured one of the world’s biggest high precision screw rotors for a major gas compression project in the Far East usi...
INDUSTRY NEWS | 2014-01-16

Sandvik Teams With Star SU for Gear Milling

Sandvik Coromant has teamed up with Star SU on an extended basis. Beginning as an authorized OEM agent, and now a national channel partne...
FEATURE ARTICLES | 2013-10-01

Untraditional Gear Machining

Look beyond the obvious, and you may well find a better way to machine a part, and serve your customer better. That’s the lesson illustrated in a gear machining application at Allied Specialty Precision Inc. (ASPI), located in Mishawaka, Indiana.
INDUSTRY NEWS | 2013-09-23

Gear Expo Recap: Sandvik Coromant Demos InvoMilling

The InvoMilling process, a unique approach to milling spur and helical gears using indexable insert cutters was front and center during G...
INDUSTRY NEWS | 2013-09-09

Ingersoll Offers Modular Milling System

Chip-Surfer from Ingersoll provides a modular milling system for NC, Swiss and live tooling applications. Highlights include interchangea...
INDUSTRY NEWS | 2013-08-13

Sandvik Expands Gear Milling Family

The CoroMill 176 range of full profile hobs for spur gears, helical gears and splines has now been extended to incorporate module 3-10 ap...
FEATURE ARTICLES | 2013-05-01

Delivering Big Gears Fast

When a customer needed gears delivered in three weeks, here’s how Brevini Wind got it done.
INDUSTRY NEWS | 2013-03-15

Vargus Offers Reliable Gear Milling Tools

A well-known gear manufacturer in the United States had an application they were currently using conventional hobbing methods on. They ha...
PRODUCT NEWS | 2013-01-01

Progress in Gear Milling

Sandvik presents the latest in gear milling technologies.
PRODUCT NEWS | 2013-01-01

Product News

The complete Product News section from the January/February 2013 issue of Gear Technology.
INDUSTRY NEWS | 2012-09-01

Industry News

The complete Industry News section from the September 2012 issue of Gear Technology.
FEATURE ARTICLES | 2012-06-01

Growing Pains - Renewables Hang on in Turbulent Energy Market

The turbines are still spinning. They’re spinning on large wind farms in the Great Plains, offshore in the Atlantic and even underwater where strong tidal currents offer new energy solutions. These turbines spin regularly while politicians and policy makers— tied up in discussions on tax incentives, economic recovery and a lot of finger pointing—sit idle. Much like the auto and aerospace industries of years past, renewable energy is coping with its own set of growing pains. Analysts still feel confident that clean energy will play a significant role in the future of manufacturing—it’s just not going to play the role envisioned four to five years ago.
PRODUCT NEWS | 2011-09-01

Reliable and Efficient Skiving

Klingelnberg's new tool and machine concept allow for precise production.
TECHNICAL ARTICLES | 2011-08-01

Manufacturing Method of Large-Sized Spiral Bevel Gears in Cyclo-Palloid System Using Multi-Axis Control and Multi-Tasking Machine Tool

In this article, the authors calculated the numerical coordinates on the tooth surfaces of spiral bevel gears and then modeled the tooth profiles using a 3-D CAD system. They then manufactured the large-sized spiral bevel gears based on a CAM process using multi-axis control and multi-tasking machine tooling. The real tooth surfaces were measured using a coordinate measuring machine and the tooth flank form errors were detected using the measured coordinates. Moreover, the gears were meshed with each other and the tooth contact patterns were investigated. As a result, the validity of this manufacturing method was confirmed.
TECHNICAL ARTICLES | 2011-03-01

Optimal Modifications of Gear Tooth Surfaces

In this paper a new method for the introduction of optimal modifications into gear tooth surfaces - based on the optimal corrections of the profile and diameter of the head cutter, and optimal variation of machine tool settings for pinion and gear finishing—is presented. The goal of these tooth modifications is the achievement of a more favorable load distribution and reduced transmission error. The method is applied to face milled and face hobbed hypoid gears.
TECHNICAL ARTICLES | 2011-01-01

Spiral Bevel Gears: Tribology Aspects in Angular Transmission Systems, Part IV

This article is part four of an eight-part series on the tribology aspects of angular gear drives. Each article will be presented first and exclusively by Gear Technology, but the entire series will be included in Dr. Stadtfeld’s upcoming book on the subject, which is scheduled for release in 2011.
PRODUCT NEWS | 2009-11-01

Cutting Gears on a Machining Center

Depo provides all-in-one machining capabilities for the gear industry.
PRODUCT NEWS | 2009-07-01

Gear Milling on Non-Gear Dedicated Machinery

Imagine the flexibility of having one machine capable of milling, turning, tapping and gear cutting with deburring included for hard and soft material. No, you’re not in gear fantasy land. The technology to manufacture gears on non gear-dedicated, mult-axis machines has existed for a few years in Europe, but has not yet ventured into mainstream manufacturing. Deckel Maho Pfronten, a member of the Gildemeister Group, took the sales plunge this year, making the technology available on most of its 2009 machines.
EVENTS | 2008-11-01

Events

The complete Events section from the November/December 2008 issue of Gear Technology
VOICES | 2008-07-01

Entrepreneurialism and Survival in the Global Market

Joe Arvin of Arrow Gear gives his insight on what it takes to succeed in today's gear industry.
INDUSTRY NEWS | 2007-01-10

Koepfer’s Versatile MZ 130 Provides Same-Setup Gear Hobbing and Worm Milling

Koepfer’s MZ130 hobbing and worm milling CNC machine from Monnier + Zahner was designed with versatility and ease of use in mind. ...
INDUSTRY NEWS | 2006-04-14

Zimmerman Presents New Milling Machine with Linear Drive

The new FZ 38 from Zimmerman is a CNC portal milling machine driven by linear motors. According to the company's press release, the ...
INDUSTRY NEWS | 2006-04-11

Bourn & Koch Expands

Bourn & Koch completed the addition of a new 20,000 square foot warehouse and a new 20,000 square foot two story engineering office build...
TECHNICAL ARTICLES | 2005-09-01

A Split Happened on the Way to Reliable, Higher-Volume Gear Grinding

Bevel gear manufacturers live in one of two camps: the face hobbing/lapping camp, and the face milling/grinding camp.
INDUSTRY NEWS | 2005-04-13

New North American Subsidiary for Atlanta GmbH

Atlanta GmbH in Bietingheim-Bissingen, Germany, announced the formation of its new North American subsidiary, Atlanta Drive Systems Inc.,...
INDUSTRY NEWS | 2005-01-28

New Lead Angle Gear Roller from Marposs

The M62 DF from Marposs is designed for the dynamic inspection of ring gears with automatic part rotation. The system can also evalua...
INDUSTRY NEWS | 2004-01-27

New Hydrodynamic Brake from Voith Turbo

Voith Turbo has designed a new industrial retarder (hydrodynamic brake) for simulating various load conditions of diesel engines. Four...
INDUSTRY NEWS | 2004-01-04

New Managers at M&M Precision

Mark Cowan and John Zahora joined M&M Precision Systems Corp. of Willoughby, OH, in different management positions. According to the ...
INDUSTRY NEWS | 2003-12-06

New Gearbox from Brevini

The S Series gearbox from Brevini features an epicyclical design that increases the available power from the unit without affecting the o...
PRODUCT NEWS | 2003-07-01

Product News

Complete Product News for July/August 2003.
TECHNICAL ARTICLES | 2002-01-01

Net-Shape Forged Gears - The State of the Art

Traditionally, high-quality gears are cut to shape from forged blanks. Great accuracy can be obtained through shaving and grinding of tooth forms, enhancing the power capacity, life and quietness of geared power transmissions. In the 1950s, a process was developed for forging gears with teeth that requires little or no metal to be removed to achieve final geometry. The initial process development was undertaken in Germany for the manufacture of bevel gears for automobile differentials and was stimulated by the lack of available gear cutting equipment at that time. Later attention has turned to the forging of spur and helical gears, which are more difficult to form due to the radial disposition of their teeth compared with bevel gears. The main driver of these developments, in common with most component manufacturing, is cost. Forming gears rather than cutting them results in increased yield from raw material and also can increase productivity. Forging gears is therefore of greater advantage for large batch quantities, such as required by the automotive industry.
INDUSTRY NEWS | 2000-01-01

Industry News

Industry News for January/February 2000.
TECHNICAL ARTICLES | 1998-05-01

Hobs & Form Relived Cutters: Common Sharpening Problems

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.
FEATURE ARTICLES | 1998-03-01

New Guideless CNC Shaper for Helical Gears

Product announcements so often trumpet minor, incremental advances with works like "revolutionary" and "unique" that even the best thesaurus can fail to offer a fresh alternative to alert the reader when something really innovative and important is introduced. In the case of Mitsubishi's new CNC gear shaper, the ST25CNC, both terms apply.
TECHNICAL ARTICLES | 1997-07-01

Involute Inspection Methods and Interpretation of Inspection Results

What is so unique about gear manufacturing and inspection? Machining is mostly associated with making either flat or cylindrical shapes. These shapes can be created by a machine's simple linear or circular movements, but an involute curve is neither a straight line nor a circle. In fact, each point of the involute curve has a different radius and center of curvature. Is it necessary to go beyond simple circular and linear machine movements in order to create an involute curve? One of the unique features of the involute is the fact that it can be generated by linking circular and linear movements. This uniqueness has become fertile soil for many inventions that have simplified gear manufacturing and inspection. As is the case with gear generating machines, the traditional involute inspection machines take advantage of some of the involute properties. Even today, when computers can synchronize axes for creating any curve, taking advantage of involute properties can be very helpful. I t can simplify synchronization of machine movements and reduce the number of variables to monitor.
TECHNICAL ARTICLES | 1997-07-01

Obtaining Meaningful Surface Roughness Measurements on Gear Teeth

Surface roughness measuring of gear teeth can be a very frustrating experience. Measuring results often do not correlate with any functional characteristic, and many users think that they need not bother measuring surface roughness, since the teeth are burnished in operation. They mistakenly believe that the roughness disappears in a short amount of time. This is a myth! The surface indeed is shiny, but it still has considerable roughness. In fact, tests indicate that burnishing only reduces the initial roughness by approximately 25%.
EVENTS | 1997-03-01

Technical Calendar

Complete Technical Calendar for March/April 1997.
TECHNICAL ARTICLES | 1996-03-01

The Effect of Metallurgy on the Performance of Carburized Gears

Gears are designed to be manufactured, processed and used without failure throughout the design life of the gear. One of INFAC's objectives (*see p.24) is to help manufacture of gears to optimize performance and life. One way to achieve this is to identify failure mechanisms and then devise strategies to overcome them by modifying the manufacturing parameters.
TECHNICAL ARTICLES | 1995-07-01

How to Avoid Errors When Measuring Step Gears

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.
FEATURE ARTICLES | 1995-01-01

How Many Mice Does It Take to Design a Gear

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.
INDUSTRY NEWS | 1994-05-01

Choosing An ISO 9000 Consultant: Why, When & How

On of the key questions confronting any company considering ISO 9000 certification is, how much is this going to cost? The up-front fees are only the beginning. Dissect the ISO 9000 certification procedure with an eye for hidden costs, and two segments of the process will leap out - the cost of consultants and the cost of making in-house improvements for the sake of passing certification. Most of these costs can be controlled by careful selection f the right consultant in the first place.
INDUSTRY NEWS | 1992-03-01

Our Experts Discuss Hobbing Ridges, Crooked Gear Teeth, and Crown Shaving

Question: When cutting worm gears with multiple lead stock hobs we find the surface is "ridged". What can be done to eliminate this appearance or is to unavoidable?
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