Determining Gear Efficiency

ExxonMobil Maximizes
Gearbox Performance
The Art and Science
of Broaching
A New Tool for
Prototype and
Production
Determining Gear Efficiency
SITE SAFETY
TOOTH TIPS
COMPANY PROFILE: Butler Gear

Q&A: Bill Moore, SKF USA
MARCH 2007
GEAR SOLUTIONS
MARCH 2007
gearsolutionsonline.com
Broaching is an extremely accurate and efcient process as

demonstrated with high volume production applications and is
unmatched by any other process. Nachi provides a wide
range of both machines and tools. Broach Tools are offered in
Conventional Gullet, Spiralglide, Spline, Blind Spline,
Full Form, Tension Draw Bar, Surface, Pot and Fir Tree styles.
We'll meet all your broaching needs!

Nachi represents the best in broach machine and tool technology.
Continued engineering design and developments showcase our
ability to meet industry needs. Think Nachi for broaching expertise,
reliable products and as your complete single source.
MARCH 2007
VOLUME 5
NO. 48
FEATURES
companyPROFILE BUTLER GEAR
18
20
DETERMINING GEAR EFFICIENCY
30
THE ART AND SCIENCE OF BROACHING
36
MAXIMIZING GEARBOX PERFORMANCE
40
CASE STUDY: A NEW TOOL FOR PROTOTYPE AND PRODUCTION
p. 20
p. 30
BY RUSS WILLCUTT
Everyone encounters obstacles, but the real challenge is in whether you cave in or
carry on. Read the story of a man who chose the lattertime and again.
BY RELLY VICTORIA PETRESCU, FLORIAN ION PETRESCU, AND NARCISA POPESCU

By analyzing certain parameters, the authors present an original method for determining the efficiency of gears.
BY CHRIS VAN DE MOTTER

To truly understand the benefits of broaching its important to take many things into
consideration, including the various methods, materials, and machines involved.
BY JEFF BIAMONTE AND TIM NADASDI, PH.D.

By choosing the proper lubricant, gearbox performance is improved. This article
describes ExxonMobils special formulation for gearbox applications.
BY ROSS WEGRYN-JONES
This case study describes the development of an involute spline form milling tool for
prototype and production applications in standard CNC milling machines.
DEPARTMENTS
p. 36
8
16
industryNEWS
17
toothTIPS WILLIAM CROSHER
New products, trends and developments in the gear-manufacturing industry.
siteSAFETY TERRY MCDONALD

Sometimes its even more important to put safety rules in place regarding processes
that you dont often perform than it is to address more familiar activities.
This installment addresses worm gear tooth forms, including descriptions of the
five standardized forms produced by milling or grinding operations.
52 Q&A
with BILL MOORE, Senior Vice President of Sales Development and

Channel Management, SKF USA
INDUSTRY RESOURCES
p. 40
45 MACHINES
48 MARKETPLACE
51 ADVERTISER INDEX
Cover Photography: Provided by ExxonMobil
MARCH 2007
GEAR SOLUTIONS
from the managingEDITOR
ne of our editorial contributors sent us an e-mail the other day asking about
the best way to direct his customers to where his article is archived on our
Web site. We explained that he could go to the home page, click on current
issue, then archived articles or download past issues, and then scroll
to the year and issue in which the article hed written appeared. We also told
him that, rather than making his customer do the work, he could download
entire issues in PDF format going back to the first one we produced in 2003,
or individual articles since the June 2005 issue. That way he could send the PDF as
an e-mail attachment with a nice message to give it the personal touch. He was also
pleased to learn that he can utilize the search function included on our site to track
down articles for his own reading. Since this wasnt the first time weve had such a
request, it got me to thinking about what a wonderful resource you have in our online
archives. As Ive mentioned, every issue weve ever produced is found on our Web site,
and whats really great is that its accessible to anyone who visits, with no membership form to fill out. Youll also find a great deal of additional information, including
press releases, our media kit, and categorized links to OEMs and other suppliers of
the products and services you need. Again, theres a lot of great information there,
and we hope youll join the thousands of people who visit us each week by going to
[www.gearsolutionsonline.com].
In this issue of the magazine were pleased to present you with a fascinating mix
of articles, starting with one by Jeff Biamonte, global lubricants marketing advisor, and Tim Nadasdi, Ph.D., product technical advisor for ExxonMobil Lubricants &
Specialties. They describe the development of the Mobilgear 600 XP Series of gear
oils, which was specially formulated for industrial gearboxes. Ross Wegryn-Jones, who
is national sales manager for Advent Tool and Manufacturing, Inc., has written a case
study on his companys development of an involute spline form milling tool for prototype and production applications in standard CNC milling machines. Three members
of the University Politehnica of Bucharests facultyRelly Victoria Petrescu, Narcisa
Popescu, and Florian Ion Petrescuhave joined forces to describe an original method
for determining the efficiency of gears, and Chris Van De Motter, president of The
Ohio Broach & Machine Company, has penned a very informative article covering all
aspects of the broaching process.
Our columnists this month are Terry McDonald, who discusses the importance of
lubricating machines properlyamong other thingsin Site Safety, and Bill Crosher
considers the development of standards for worm gear tooth forms in Tooth Tips.
Butler Gear is this months company profile, and we think youll find the story of Hilton
Treudenas well as his sons, Tom and Leeto be both interesting and inspirational.
Bill Moore, who is senior vice president of sales development and channel management for SKF USA, discusses the many benefits of developing a good relationship with
your local distributor in our Q&A department.
Id like to thank everyone whos submitted articles for consideration recently. We
do everything we can to publish those we feel will be of benefit to our readers, and
were always excited to welcome new writers and companies into our pages. If you
havent already, please send any article ideas you may have to the e-mail address
found below. All best:
Russ Willcutt
Managing Editor
Gear Solutions magazine
editor@gearsolutionsonline.com
(800) 366-2185
GEAR SOLUTIONS
MARCH 2007
PUBLISHED BY
MEDIA SOLUTIONS, INC.
P. O. BOX 1210 PELHAM, AL 35124
1-800-366-2185
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P UBLIS HER
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V I CE P RES IDENT
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N AT I ON AL SAL ES MANAGER
BRAD WHISENANT
OPE RAT I ON S/ CIRCULATIO N

TERESA HALL
ADM I N I ST RAT I V E AS S IS TANT

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PRODUCTION
ART DIRECTO R
JEREMY ALLEN
EDITORIAL
M AN AGING EDITO R
RUSS WILLCUTT
CON T RI BU T I NG WRITERS
JEFF BIAMONTE
WILLIAM P. CROSHER
TERRY MCDONALD
TIM NADASDI, PH.D.
FLORIAN ION PETRESCU
RELLY VICTORIA PETRESCU
NARCISA POPESCU
CHRIS VAN DE MOTTER
ROSS WEGRYN-JONES
VOLUME 5
NO. 48
Gear Solutions (ISSN 1933 - 7493) is published monthly by

Media Solutions, Inc., 266D Yeager Parkway Pelham, AL. 35124.
Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals postage pending at Pelham
AL. Printed in the USA. POSTMASTER: Send address changes
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Publications mail agreement No. 41395015 return undeliverable
canadian addresses to P.O. Box 503 RPO West Beaver Creek
Richmond Hill, ON L4B4R6. Copyright 2006 by Media Solutions,
Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic
or mechanical, including photocopy, recording, or any information
storage-and-retrieval system without permission in writing from the
publisher. The views expressed by those not on the staff on Gear
Solutions magazine, or who are not specifically employed by Media
Solutions, Inc., are purely their own. All "Industry News" material has
either been submitted by the subject company or pulled directly from
their corporate web site, which is assumed to be cleared for release.
Comments and submissions are welcome, and can be submitted to
editor@gearsolutionsonline.com
New Products, Trends and Developments

in the Gear-Manufacturing Industry
Gleason Corporation News

Gleasons latest addition to its line of advanced, highly productive grinding machines is the 300TWG Threaded Wheel Grinding
Machine, designed to deliver the industrys fastest floor-tofloor times for grinding of cylindrical gears up with a diameter
up to 300mm. The new 300TWG uses high-speed direct-drive
spindles and advanced Siemens CNC controls with Gleason
software to take full advantage of the latest multi-start grinding
wheels. Multi-start grinding wheels are capable of improving
production rates up to five or 10 times that of conventional
single-start wheels. In addition, the 300TWG can be equipped
with a patented Gleason diamond-plated master dressing gear
system that can dress a multi-start grinding wheel in a very
short time, regardless of the number of starts, making it ideal
for higher volume production environments.
Users also have the option of applying a compact, fully automatic CNC dressing unit located just above the grinding head
for conventional dressing with diamond plated dressing discs.
This is the optimal for the smaller batch requirements of job
shop or prototype production. The 300TWG is also offered with
an optional high-speed, fully automated two-station ring loader,
with easy integration of a spin-dry station if needed.
The 300TWG provides exceptional rigidity for a grinding
machine, derived from the use of the standard Gleason hobbing machine basea proven design that provides significantly
enhanced stiffness and stability as compared to other conventional grinding platforms.
Gleason has also announced
that Gary J. Kimmet, vice
president worldwide sales
and marketing, has been
appointed president of the
Gear Research Institute (GRI).
The institute, affiliated with
the ASME and the AGMA, provides gear and related technological information and support by conducting research
and development, consulting, analysis, and testing.
Since its inception in 1982, the GRI has conducted programs

in important technology areas, including gear materials, heat
treat, noise characteristics, durability, and many others. Dr.
Suren Rao, managing director of the GRI and senior scientist
of the Drivetrain Technology Centerboth located at Penn
State Universitysays, The Board of Trustees was pleased
to appoint Mr. Kimmet to this prestigious position, and to continue our relationship with a world leader in gear technology like
Gleason.
Kimmet joined Gleason Corporation in 1968 and has held
a number of positions with the company, including that of
vice president of engineering. In his current position he is
responsible for the marketing of Gleason Corporation products
worldwide. He holds patents related to gear manufacturing and
processes and has published and presented technical papers
on gear technology. He received both his bachelors and masters degrees in mechanical engineering from The Ohio State
University. He received the Lamme Award from Ohio State for
outstanding alumni contributions to the field of engineering.
He is a past member of the Board of Directors of the AGMA
and has been a member of the Board of Trustees of the Gear
Research Institute for nearly 10 years. Kimmet is also a member
of the Board of Directors of the Gleason Foundation.
For more information go online to [www.gleason.com].
TO SUBMIT:
Companies wishing to submit materials for inclusion in Industry News should contact Managing Editor Russ Willcutt at editor@gearsolutionsonline.com.
Releases accompanied by color images will be given first consideration.
GEAR SOLUTIONS
MARCH 2007
Bison Gear Appoints

New President
Bison Gear & Engineering Corp., a leading manufacturer of fractional horsepower gearmotors and electric motors, has
announced the appointment of Martin
Swarbrick as president and chief operating officer. Most recently Swarbrick was
vice president and director of business
excellence for Motorola. He led the
path to national recognition for performance excellence when Motorola was
awarded the Malcolm Baldrige National
Quality Award in 2002 and the Balanced

Scorecard Hall of Fame award in 2004.
Martins track record as a leader in
the disciplines of performance excellence, quality, customer advocacy, and
Six Sigma will drive Bison Gears continued growth by offering the best overall
value package to customers, says Ron
Bullock, Bisons chairman and CEO.
Swarbricks 27 years as a business
leader began in Ireland as a manufacturing engineer for General Electric, where
over a seven-year period he progressed
to manufacturing manager. He spent
the next seven years with Verbatim
(Kodak) as operations manager. In
1991 he became operations director for
Motorolas Land Mobile Products Sector,
and shortly after became vice president
and general manager with responsibility
for manufacturing operations and distribution for Europe, the Middle East, and
Africa.
Born in Cork, Ireland, Swarbrick was
educated at Trinity College, Dublin,
and holds degrees in engineering and
mathematics. He studied manufacturing and operations at IMD in Lausanne,
10
GEAR SOLUTIONS
MARCH 2007
Switzerland, and completed the Leadership Institute at

Northwestern Universitys Kellogg School of Management
in 2001.
With robust fractional horsepower gearmotor designs
offering up to twice as much torque in the same package
size as competitors, Bison Gear & Engineering Corp. continues to build upon a strong engineering tradition begun in
1960. Bison designs and produces gearmotors in parallel
shaft and right angle configurations, as well as AC and DC
motors only, for OEMs worldwide who demand the best longlifetime value.
For more information contact Brenda Clemetson at (630)
443-5797 or bclemetson@bisongear.com. Go online to
[www.bisongear.com].
New Tool Presetting

Systems from BIG Kaiser
BIG Kaiser Precision Tooling, Inc., introduces the new STP35 Basic and STP-35 EzVision System. The system matches
the superior accuracy and T.I.R. of the STP-34, and has an
extended z-axis height to accommodate tools up to 20 inches in length. The system has display resolution of .001mm
(.00004) for added precision.
The EzVision systems quick gage capability will measure
any tool. It manages and displays tooling and cutting edges
on the same monitor as the Speroni PC-based EzVision
control. The system features one-micron Heidenhein glass
scales. Its thermo-balanced and artificially aged pearlitic
cast iron structure ensures that the equipment is fully isostatic and will not deform or distort over time or temperature
changea fundamental requirement in providing long-term
linear accuracy and repeatability.
Digital tool sensing removes the potential for error inherent in manual measurement systems. They system does not
rely on the operators sight and judgment to focus and align
tools within its optics. It assures reproducibility of precision
settings, no matter which operator uses the instrument.
After inserting the tooling in the STP-35 EzVisions spindle,
the operator sets maximum diameter by reading simple digital values and following color codes on a personal computer monitor. Obtaining
measurement values
is as easy as aligning
the tool within the field
of view or using one
of the custom measurement macros. The
computer replaces the
digital readout used
on many other types
of presetters, so the
operator does not have
to learn to operate two sets of controlsboth digital readout
and computer monitor.
The EzVision control features a centering indicator box
MARCH 2007
GEAR SOLUTIONS
11
that is ideal for presetting angular cuts,

as in chamfering. It may also be used to
calculate nose radii and angles. Episcopy,
one of the STP-35s most popular options,
provides an easy way to detect defects or
deformities by illuminating and magnifying
the cutting edge.
As with all offline tool presetters, the
new STP-35 optimizes tool resources by
reducing tool set-up time and improving

machining production time, while also
enhancing the production of quality components.
To learn more call (888) TOOL-PRO/8665776, send e-mail to bigkaiser@bigkaiser.
com, or go to [www.bigkaiser.com].
Paulo Adds Surface

Treatment Capabilities
Paulo Products Company announces the
addition of two surface treatments at
its St. Louis, Missouri, facility. Paulo-St.
Louis now has the capability to perform
gas nitriding. Gas nitriding is carried out
in a sealed retort with an ammonia atmosphere at temperatures at or near 1,000
degrees Fahrenheit. Typical cycle times
range from 24 hours to 72 hours. PauloSt. Louis can accommodate parts up to
48 inches in length. In addition, Paulo-St.
Louis has added the capability to perform
a corrosion resistant ferritic nitrocarburizing process on carbon and alloy steels.
This new process incorporates an oxidizing stage that enhances corrosion resistance as well as improving appearance
and overall performance. Paulo-St. Louis
continues to offer Nitro-Wear, a patented
ferritic nitrocarburizing process performed
in a fluid bed.
Paulo has operated a commercial heat
treating facility in St. Louis since 1943.
Paulo-St. Louis is one of the largest and
most complete heat treating facilities in
the region, offering continuous belt, batch,
vacuum, induction heat treating, furnace
brazing, cryogenics, and black oxiding.
Paulo provides a wide variety of innovative engineered solutions in heat treating,
brazing, and metal finishing. Paulo also
offers its customers a broad range of metallurgical services and extensive engineering resources.
For more information about Paulo contact Jim Heman, vice president of sales
and marketing, at (314) 450-4366. Go
online to [www.paulo.com].
Bodine Announces
Important Internal
Promotions
Bodine Electric Company has announced
important changes to its leadership team.
The company has promoted Michael
Gschwind to vice president of sales and
marketing. Additionally, Edmund Glueck
has been promoted to marketing and
product development manager, and Terry
Auchstetter has been promoted to business development manager for custom
products.
12
GEAR SOLUTIONS
MARCH 2007
Gschwind, who has been with the company for nearly

30 years, has been instrumental in all aspects of product
research, development, and sales. He began his career at
Bodine as a sales engineer, directly serving accounts in
the Midwest and Western United States. In the mid-1980s
Gschwind transferred to Bodines Research and Development
group, where he developed electronic products for stepper
and brushless DC motors. In 1999 he became engineering
manager for Bodines AC, brushless DC, and e-TORQ product
lines. In 2002 he was named director of sales, where he
managed the companys corporate sales force. Gschwind
holds multiple degrees, including a bachelors in electrical engineering and a master of engineering management
degree from Northwestern University.
Mikes experience in product design, his extensive knowledge of motor system applications, and strong understanding of sales make him a welcome addition to our executive
team, says John Bodine, president and CEO.
Both Glueck and Auchstetter have extensive experience in
marketing and applications for the Bodine product line. Since
joining the company in 1993, Glueck has been responsible
for market development and sales of all of Bodines AC and
Brushless DC products. In his new role he will oversee all
Bodine marketing activities. Auchstetter, who has been with
Bodine for 21 years and most recently has supervised all DC
and control products, will assume responsibility for managing opportunities for custom (built-to-order) products.
Im confident these changes will allow us to focus our
efforts in a consistent, customer-driven manner, Gschwind
says. The end result will be enhanced growth in markets
that demand the highly reliable, value-added products and
services offered by Bodine.
To learn more call (773) 478-3515, (800) 7-BODINE, or
send e-mail to info@bodine-electric.com. Go online to [www.
bodine-electric.com].
INDEX Offers Single-Spindle CNC Bar

Machine
With the new C65 CNC Single Spindle Bar Machine, INDEX
continues a 90-year tradition of successful single-spindle
bar automatics. The C65 can include a heavy-duty counterspindle and Y-axis for extended machining flexibility and
increased speed. According to Index, the new model offers
new levels of both productivity and flexibility for work done
from bar stock.
With optional 42mm (1 5/8inch), or 65mm (2 inch) bar
capacity, a maximum spindle speed of 6300, respectively
5000 RPM at 20KW or 26Hp at 100-percent (60min) duty rating and 105Nm (77ftlbs) torque, the C65 has enough power
to do a lot of work in a short time. Despite its large working
range, the machine exhibits a compact screw machine size
design, requiring little floor space so it fits into every shop
that runs screw machines.
Both turret slides and the counter-spindle slide offer a
www.techinduction.com
MARCH 2007
GEAR SOLUTIONS
13
1g acceleration rate, and rapid traverse

rates of 25 and 50m/min (75 and 150 ft/
min), adding to the productivity because
of its faster motions. These production
advantages can often become essential
for the survival of a business, particularly for job shops.
Speed: Three tools are in cut simultaneously almost all the time. And a
counter-spindle equipped with the usual
Z-axis and X-axis allows the
user to complete parts very
quickly. Both axes are electronically coupled with the
second turret (slave- axes).
As a result, the third turret
can be working on the part
in the counter spindle while
the other two turrets work
on the main spindle, so that
three tools may be in cut
simultaneously.
Flexibility: Two Y-axes
for the turrets and a very
powerful counter spindle
14
GEAR SOLUTIONS
MARCH 2007
provide flexibility unmatched by other

automatics for machining even complex
parts without compromising speed or
productivity.
An additional innovation is the polygon
generating capability, which results from
the counter-spindle operating as a polygon generating attachment. The actual
polygon generating head is mounted
directly on the face of the chuck. No
additional equipment is required. The

very high rotational inertia and stiffness
of the counter spindle assures vibrationfree cuts, as well as long tool life, even
on alloy steel.
An innovative highlight of the machine
is in the design of the guide-ways for the
turrets. The slides are not based on the
traditional linear system, but on a highly
innovative plate-type slide system. The
slide surfaces are made of a match

between a cast iron plate, and steel
strips with ceramic-coated slides. This
slide system offers significant advantages over the traditional slide ways: several times greater stiffness, improved
dampening characteristics, and it is
more compact. The actual axis drive is
accomplished by rod-kinematic drive
linkages arranged on the rear of the cast
iron machine bed.
To learn more call (317) 770-6300,
send e-mail to sales@index-usa.com, or
go to [www.index-usa.com].
Ball and Roller Screw

Assemblies from SKF
SKF
ball screws and roller screws are

available in a variety of cost-effective
types and designs to promote precise
positioning in linear-actuation applications for the automotive, aerospace,
injection molding, instrumentation, medical, and machine tool industries, among
others. The extensive product line
includes rolled ball screw and ground

ball screw assemblies and planetary and
recirculating roller screws for especially
demanding applications.
Types of rolled ball screws include
miniature, universal and precision versions, and long lead ball screws. Ground
ball screws are offered both in preloaded
and non-preloaded designs. Uniquely
engineered TCM precision types feature a robust and durable internal return
design. All assemblies can be equipped
with accessories for screw shafts and
nuts and can be supplied with the
necessary support-bearing package preassembled and ready to go.
Planetar y and recirculating roller
screws particularly suit applications
requiring accuracy, rapid acceleration,
fine leads, and high load capacities.
They can sustain static loads up to
1,000 tons and dynamic loads up to
200 tons. All roller screws are available in various styles and a full range
of diameters and leads to enable opti-
mum rotational speed and acceleration

capabilities. SKF ball screws and roller
screws can further be customized to satisfy customer specifications.
For more information call Kyle G.
Fedorcha at (800) 541-3624 or 610-8613709. Visit online at [www.linearmotion.
skf.com].
MARCH 2007
GEAR SOLUTIONS
15
siteSAFETY
terryMcDONALD
Member of the ANSI Subcommittee on Gear Safety
Sometimes its even more important to put safety rules in place regarding equipment and processes that you
dont often perform than it is to address more familiar activities and tasks.
hope that you all had a ver y happy

Valentines Day and are looking forwardas I amto warmer weather.
Remember to ask your employees to
drive carefully this time of year. One of the
spotlights in this issue of Gear Solutions is
lubrication. We have previously discussed
the importance of proper lubrication on
machines from a safety standpoint, but it
definitely bears repeating. The lack of proper lubrication on a gear hobbing machine
can cause mechanical problems to the
machine, of course, but it can also create
a ver y hazardous situation for the operator
as well as other employees in the area. As
we all know, in the hobbing process both
the cutter and the hob are rotating as the
gear teeth are being cut. If, due to the
lack of proper lubrication, one or the other
spindles on the machine stop, not only
will the cutter and the part be damaged,
but there is a ver y real chance for the cutter, the part, or both to come flying out of
the machine, possibly creating a serious
injur yor even worse.
There are many other problems created
by improper lubrication, not the least of
which is the loss of production when the
machine must be put out of ser vice for
repairs. We must maintain our machines,
which at the ver y least involves a program
of maintaining the proper lubrication in the
machine. Most machine manufacturers are
happy to provide a lubrication schedule,
and if the manufacturer is no longer in busi-
ITS DEFINITELY BETTER TO TAKE A

LITTLE EXTRA TIME TO PERFORM A
TASK SAFELY RATHER THAN LOSING
THE ABILITY TO EVER DO THAT PARTICULAR TYPE OF PROJECT AGAIN.
ness we are ver y fortunate in this countr y
to have a large network of used machiner y
dealers and rebuilders that can furnish the
necessar y information. I highly recommend
that you check your records to assure that
this information is readily available to your
employees. If you are having any problems
acquiring the correct information for your
equipment, please contact me and I will be
happy to tr y to assist you.
Another subject in the magazine this
month is broaching. For many of us in
the gear industr y this is a process that is
only occasionally used in our facility, and
it is therefore a process that we are not
as familiar with as we should be. This is
a safety concern in itself. How many of
us address these processes that we only
occasionally use in our safety manuals? I
would be willing to bet that many of these
processes are often ignored, from a safety
standpoint. Each of these processes have

their own safety concerns, and they must
be addressed. Are the employees assigned
to these jobs suitably trained? Are they
given the proper safety instructions prior to
operating this equipment? Have all of the
necessar y safety factors been taken into
consideration? I see many shops operating broaching equipment that has been in
use for many years and is not equipped
with the proper guarding, or even operating
controls. This is a ver y real safety hazard
that must be addressed, particularly in
the case of the shops that only use this
equipment occasionally. I urge you to take
a close look at this equipment and correct
any safety hazards that exist.
In my last column we discussed the
safety issues involved with the use of
hand tools. While thinking about writing
this installment last evening, I caught an
episode of Home Makeover on the tube.
During this particular show one of the stars
was ver y seriously injured while operating
a hand grinder. It just points out that any
of us, even a well-trained professional, can
be seriously injured or even killed while
doing something we often take for granted.
We all need to take a step back and look at
what we are doing. We need to make sure
that we are not the cause of an accident.
Its definitely better to take a little extra
time to per form a task safely rather than
losing the ability to ever do that particular
type of project again.
ABOUT THE AUTHOR:

With more than 30 years of experience in the gear industr y, Terr y McDonald is par tner and manager of Repair Par ts, Inc., and a current member
and past-chairman of the American National Standards Institute B11.11 Subcommittee on Safety Requirements for Construction, Care, and Use of
Gear Cutting Equipment. McDonald writes this monthly column specifically for Gear Solutions magazine, and he can be reached at (815) 968-4499
or rpi@repair-par ts-inc.com. The companys Web site is [www.repair-par ts-inc.com].
16
GEAR SOLUTIONS
MARCH 2007
toothTIPS
williamCROSHER
Author, engineer, and former director of the
National Conference on Power Transmission
This installment addresses worm gear tooth forms, including descriptions of the five standardized forms
produced by milling or grinding operations.
here is a wide choice in tooth forms,

each form with its own share of merits
and demerits depending on the application. Several forms are associated with a
trade name. Under the optimum conditions for
any worm gear tooth profile, only line contact
is present when two gears of finite diameter
mesh and are rotated. Depending on the flexing that takes place a contact area is only
produced under load and by a corresponding
elastic deformation of the tooth surfaces. The
rotating worm develops a series of rack profiles
advanced along its axis. The center section
has identical pressure angles on both sides,
but off-center the sections lose their symmetry.
The hob has an identical series of rack sections
generating the worms teeth. The conjugate
action being the same as that between a rack
and a pinion. It is the worms geometry that
decides the type of tooth form that is required.
Early on worm gear design fell into one
of three groups: non-throated, single-throated
(cylindrical), and double-throated (globoidal).
Non-throated worm gears only have point contact. The teeth are not curved and do not envelop the worm. Any load will produce rapid wear,
and to all intents and purposes this group can
be ignored. ISO made the first attempt at cylindrical worm standardization in 1968, resulting
in five forms being standardized in ISO and
AGMAs 6022-C93. These five are designated
ZA, ZN, ZK produced with a milling cutter, and
ZK and ZI with a grinding operation. The thread
forms are closely related to the manufacturing
process:
Type of machining; e.g. turning, milling, and/
or grinding
The shape of the edges or surfaces of the
cutting tool
Position of the tool relative to an axial plane
of the worm
Where relevant, the diameters of disc type
tools or grinding wheels
ISO MADE THE FIRST ATTEMPT

AT STANDARDIZATION IN 1968,
RESULTING IN FIVE FORMS
BEING STANDARDIZED IN ISO
AND AGMAS 6022-C93.
Flank Form A: straight sided axial type ZA
The angle of generation and straight shape
producing line lie in one axial section. The line
of the cutter and the tooth flank generator of
the worm coincide, cutting the worm axis. The
thread flank is always a straight line in the axial
plane. A trapezoidal cutter has its edge lying
in the axial section and can cut both flanks
simultaneously. The form can be produced with
a straight sided lathe tool, milled, skived, or
ground. Another method is the inversion of the
process of cutting a helical gear with a rack cutter. A grinding wheel or rotary milling cutter with
a convex profile. In the transverse section the
profile is part of an Archimedian spiral. A trade
name associated with this form is Durand.
Flank Form N: straight sided in normal plane
of thread space helix type ZNThe straight
producing line and the angle of generation lie in
a plane inclined to the worm axis by the reference lead angle. Although, as with a ZA form,
the cutter form and tooth line coincide, they do
not in this form cut the worm axis. The cutter
is set at the level of the axis so that the cutting face lies in the inclined plane of the lead
angle. The form can be produced with a conical milling cutter/grinding wheel or skiving. A
suitably profiled cutter allows the cutting edge
to progress tangentially from one end of the
face to the other. The profiles are approximate
because of effect due to change of helix with
change in thread height. These are sometimes

produced in a lathe with a trapezoidal form tool
with edges in the cutting plane that match the
profile of the thread space in a plane normal to
the reference helix of the thread space.
Flank Form I: involute helicoid worm type
ZIThe tooth form are sections of an involute
helicoids surface, which is tangential to a
plane slanted to the axial section by the lead
angle, and inclined to the worm axis by the
generating angle. This tangential plane and
the worm tooth flank meet in a straight line,
which is the flank generator. This line lies in a
tangential plane to the base cylinder.
Flank Form K: milled helicoids generated
by biconical grinding wheel or milling cutter,
convex profiles in axial planesUnlike forms
A, I, and N this form does not have straight line
geneatrices. The worm tooth flanks are tangential to a double cone, whose axis intersects the
worm axis at the selected lead angle. The cone
lines are straight shape producing lines which,
with the normal to the worm axis, form the generation angle. The angle is located in the plane
of intersection which also contains the cone
axis. It is cut and/or ground with a bi-conical
straight sided milling cutter or grinding wheel.
The tool axis is tilted to the lead angle of the
thread at its mean diameter. The center plane
of the cutter intersects the worm axis at the
centerline of the space between the threads.
Form ZC: concave axial profile formed by
machining with a convex circular profile disc
type cutter or grinding wheelUnlike forms
ZA, ZI, and ZN they do not have straight line
geneatrices. They are generated with a rotary
bi-convex disc type milling cutter or grinding
wheel, similar to generating the AK form. Four
tool dimensionsprofile radius, mean diameter, pressure angle, and thicknessdetermine
the form. The advantage of the AK form is that
adjustments can be made to accommodate
for changes in tool diameter by modifications
to the tool radius and angle. The proprietary
name is Cavex.
ABOUT THE AUTHOR:

William P. Crosher is former director of the National Conference on Power Transmission, as well as former chairman of the AGMAs
Marketing Council and Enclosed Drive Committee. He was resident engineer-North America for Thyssen Gear Works, and later at Flender
Graffenstaden. He is author of the book Design and Application of the Worm Gear.
MARCH 2007
GEAR SOLUTIONS
17
companyPROFILE
ilton Treuden was not a man who

allowed a setback to get him down
for long. When one road ended, he
simply forged a new course of his
own. Strangely enough, the first obstacle he encountered actually involved a
road.
Hed started a greenhouse operation
in Milwaukee straight out of high school,
selling plants and flowers, and within a
year he was doing so well that he bought
the building that he was leasing, says
Tom Treuden, recalling his father. But
then the city leveled the structure when
it decided to build a new road, so he
was back to square one.
Rather than starting over again in a
new location, he decided to enter the
police academy, but after 11 years on
the force he grew tired of his future
18
GEAR SOLUTIONS
MARCH 2007
being in someone elses hands, so he

realized that it was time to exit that
road and find a new direction. He had
a friend who worked in a local gear
shop, and they decided to go into business for themselves. Thats when Hilton
Treuden mortgaged his house, bought
his first gear machine, leased a nearby
garage, and Butler Gearnamed for
the Wisconsin city in which it is still
foundwas born.
Growing up, Tom Treuden spent plenty
of time around the shop, washing windows, sweeping floors, and cutting the
grass for 50 cents an hour. He joined
the company on a full-time basis after
graduating from high school in 1974,
running a lathe for about three years
before moving up to a gear cutter and
eventually learning to operate all of the
companys machines. I spent about 20

years on the shop floor before I moved
into management in the mid nineties,
he says, so theres nothing here that I
havent doneand that includes driving
the truck and cleaning out the toilets.
Ive always thought that, no matter what
your actual position is, youve got to
be willing to do whatever needs to be
done.
That included stepping into the role
of company president the day after his
father passed away in 2002. His brother, Lee, who is vice president, grew up
working at the shop as well, and after a
stint of military service he came on fulltime to oversee the companys production and maintenance activities.
Since its beginnings in a tiny rented
garage in 1960, Butler Gear has moved
BUTLER GEAR
EVERYONE ENCOUNTERS OBSTACLES, BUT THE REAL CHALLENGE IS IN WHETHER YOU CAVE IN OR
CARRY ON. THIS PROFILE TELLS THE STORY OF A MAN WHO CHOSE THE LATTERTIME AND AGAIN.
By Russ Willcutt
numerous times, most recently into a

46,000 square-foot facility manned by
some 50 experienced employees. It
was originally 38,000 square feet, but
we soon added another 8,000 to that
so we could meet the growing demand
for our products, Tom says. Our customers have really been good to us, and
theyve supported us, which is a great
incentive to do the best work you possibly can.
Its also great advertising. Not a
week goes by when we dont get a call
from a new customer who says Ive
got a friend who buys from you, and he
told me that I should, too, he says,
And this guy might be from New York,
down in the Carolinas, in Florida, Texas,
or out on the West Coast. So we really
dont need a sales department since
the reputation weve worked hard to

build over the years is working so well in
terms of attracting new business. There
are a lot of people out there who know
about Butler Gear.
Part of the reason for this is the
Treudens decision to separate the company from its competitors by offering a
maximum range of capabilities. Some
of that has to do with the equipment
weve purchased, Tom says. Anybody
can cut a five-inch gear, but not everybody can produce 65- and 70-inch
gears, like we can. But weve also made
a point of excelling at the more complex
gearing that nobody else wants to take
on. So I think that people have come to
know that, if theyve got a complicated
job that they need done, were somebody they can trust to handle thatand
to do it right the first time.

Asked if he inherited his fathers
green thumb, Tom Treuden laughs and
admits that I cant even keep a houseplant alive, but there is something
more important that he and his brother
have allowed to thrivetheir fathers
legacy. And it brings me great joy to
know that, he says. I know that he
struggled, but he always managed to
provide for his family, and Ive learned
from his lessons as well as his mistakes.
People still call us all the time and
ask to speak to Hilton, and theyre so
sorry when I tell them that hes no longer around, Tom says. But thats just
proof of the kind of man he washe
touched a lot of people, and he couldnt
be held down.
FOR MORE INFORMATION:

Call (262) 781-3270, send e-mail to gears@butlergear.com, or visit online at [www.butlergear.com].
MARCH 2007
GEAR SOLUTIONS
19
De
te
r
Ge m
By
Re
ar
lly
By
ana
lyzi
ng
Vic
tor
ia
Pe
Ef
tr e
sc
u,
Flo
if n
ria
ici
i
en n
cy
Ion
cer
Pe
orig
tr e
t
a
sc
i
np
inal
u,
an
a
met
dN
r
am
ar c
hod
e
isa
ters
for d
Po
pe
,
the
eter
sc
u
aut
min
hor
ing
the
s pr
effic
ienc esent
a
y of
gea n
rs.
20
GEAR SOLUTIONS
MARCH 2007
bstract: This paper presents an original method for determining the efficiency of the gear. The originality
of this method relies on the eliminated friction modulus. In the following pages we analyze the influence
of a few parameters concerning gear efficiency. These parameters are: z1the number of teeth for the
primary wheel of gear; z2the number of teeth of the secondary wheel of gear; the normal pressure angle on the
divided circle; and the inclination angle. With the relations presented in this paper, one can synthesize the gears
mechanisms. Today, gears are present everywhere in the mechanical world, especially the automotive, electronics, and
energy industries, etc. By optimizing this mechanism, one can improve the functionality of transmission gears.
MARCH 2007
GEAR SOLUTIONS
21
Introduction
In presenting this original method for calculating the efficiency of the gear,
the originality consists in the way of determining the gears efficiency,
because we havent used the friction forces involved in couplingthis new
way eliminates the classical method, in fact. The necessity of determining
the friction coefficients by different experimental methods is eliminated, as
well. The efficiency determinates by the new method are the same as in the
classical method; namely, the mechanical efficiency of the gear. Precisely,
one determines the dynamics efficiency, but at the transmissions gears,
the dynamics efficiency is the same as the mechanical efficiency.
Determining the Momentary Dynamic (Mechanical)

Efficiency
The calculating relations [2, 3], are the next (1-21), (see fig. 1):
with: Fm - the motive force (the driving force);

F - the transmitted force (the useful force);
F - the slide force (the lost force);
v1- the velocity of element 1, or the speed of wheel 1 (the driving wheel);
v2- the velocity of element 2, or the speed of wheel 2 (the driven wheel);
v12- the relative speed of the wheel 1 in relation with the wheel 2 (this is
a sliding speed).
FIGURE 1: THE FORCES OF THE GEAR
The consumed power (in this case the driving power):
22
GEAR SOLUTIONS
MARCH 2007
The useful power (the transmitted power from the profile 1 to the
profile 2) will be written:
The Geometrical Elements of the Gear
The lost power will be written:
One determines the next geometrical elements of the external gear,

[2,3], (for the right teeth, =0):
The radius of the basic circle of wheel 1 (of the driving wheel), (7):
The momentary efficiency of couple will be calculated directly with

the next relation:
The radius of the outside circle of wheel 1 (8):
One determines now the maximum pressure angle of the gear (9):
The momentary losing coefficient [1], will be written:
And now one determines the same parameters for the wheel 2, the
radius of basic circle (10) and the radius of the outside circle (11)
for the wheel 2:
One can easily see that the sum of the momentary efficiency and the
momentary losing coefficient Now one can determine the geometrical
elements of the gear. These elements will be used in determining the
couple efficiency, .
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MARCH 2007
GEAR SOLUTIONS
23
Now one can determine the minimum pressure angle of the external gear (12, 13):
The
RIGHT CHOICE
for
Machines,
Services and
Tooling for the
Gear Industry
Now one can determine, for the external gear, the minimum (13) and the maximum (9) pressure angle for the right teeth. For the external gear with bended teeth (0) one uses the
relations (14, 15 and 16):
For the internal gear with bended teeth (0) one uses the relations (14 with 17, 18-A or
with 19, 20-B):
A. When the driving wheel 1 has external teeth:
Print and Online

Services Available
B. When the driving wheel 1 has internal teeth:
1.800.366.2185
z1 cos t
cos
cos1m =
z1
2
cos
Published by Media Solutions, Inc.

P.O. Box 1210
Pelham, AL 35124
24
GEAR SOLUTIONS
MARCH 2007
Determining the Efficiency

The efficiency of the gear will be calculated through the integration of momentary efficiency on all sections of gearing movement, namely
from the minimum pressure angle to the maximum pressure angle, the relation (21), [2, 3]:
=
i d =
am
cos 2 d =
M
1
1
[ sin( 2 ) + ]
=
2 2
m
1
sin( 2 M ) sin( 2 m )
sin( 2 M ) sin( 2 m )
=
[
+ ] =
+ 0. 5
2
2
4 ( M m )
(21)
More precise (5) for determining momentary efficiency is the relation (22):
i = cos2 1
1
2
i = cos 1
1 + cos2 1 (
+ tg 1 )
z1 2 z1
(5)
(22)
Conclusion
The input parameters are: z 1 = the number of teeth for the driving wheel 1;
z 2 = the number of teeth for the driven wheel 2, or the ratio of transmission, i (i 12=-z 2/z 1);
0 = the pressure angle normal on the divided circle;
= the bend angle.
MARCH 2007
GEAR SOLUTIONS
25
The efficiency of the gear increases when the number of teeth

for the driving wheel 1, z1, increases too, and when the pressure
angle, 0, diminishes. In addition, z2 or i12 are not much influence
on the efficiency value.
One can easily see that for the value 0=20, the efficiency takes
roughly the value 0.89 for any values of the others parameters
(this justifies the choice of this value, 0=20, for the standard
pressure angle of reference). The better efficiency may be obtained
only for a 020, the efficiency takes roughly the value 0.89 for
any values of the other parameters (this justifies the choice of this
value,0 =20, for the standard pressure angle of reference). The
better efficiency may be obtained only for a 0 20. But the pressure angle of reference, 0, can be decreased at the same time the
number of teeth for the driving wheel 1, z1, increases, to increase
the gears efficiency.
The module of the gear, m, has no influence on the gears efficiency value. When 0 is diminished one can take a higher normal
module for increasing the addendum of teeth, but the increase of
the m at the same time with the increase of the z1 can lead to a
greater gauge. The gears efficiency, , is really a function of 0
and z1: =f(0,z1); m and M are just the intermediate parameters.
For good projection of the gear its necessary to have a z1 and z2
greater than 30-60, but this condition may increase the gauge of
mechanism.
In this paper we have discussed how one determines the dynamics efficiency, but at the transmissions gears the dynamics efficiency is the same as the mechanical efficiency. This is a greater
advantage of the transmissions gears. This advantage of the
gears mechanisms may be found at the cams mechanisms with
plate followers, as well.
REFERENCES:
1. Pelecudi, Chr., .a., Mecanisme. E.D.P., Bucureti, 1985.
2. Petrescu, V., Petrescu, I., Randamentul cuplei superioare de la angrenajele cu roi dinate cu axe fixe, In: The Proceedings of 7th National
Symposium PRASIC, Braov, Romania, vol. I, pp. 333-338, 2002.
3. Petrescu, R., Petrescu, F., The gear synthesis with the best efficiency,
In: The Proceedings of ESFA03, Bucharest, Romania, vol. 2, pp. 63-70,
2003.
4. Petrescu, R., Petrescu, F., Gears design for the mechanisms highest
efficiency. In: The Proceedings of ICEGD05, Bucharest, Romania, vol. I,
pp. 257-260, 2005.
5. Petrescu, R.V., Petrescu, F.I., Determining the dynamic efficiency of
gears. In: The Proceedings of SYROM05, Bucharest, Romania, vol. II,
pp. 381-386, 2005.
ABOUT THE AUTHORS:

Relly Victoria Petrescu is a lecturer and Narcisa Popescu is an
associate professor in the Depar tment of Descriptive Geometr y
and Engineering Graphics at the University Politehnica of
Bucharest. Florian Ion Petrescu is an assistant professor in the
universitys in Depar tment of Mechanisms and Robots.
28
GEAR SOLUTIONS
MARCH 2007
The Art and Science of Broaching

By Chris Van De Motter
30
GEAR SOLUTIONS
MARCH 2007
To truly understand the benefits of

broaching its important to take many
things into consideration, including
the various methods, materials, and
machines involved.
MARCH 2007
GEAR SOLUTIONS
31
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roaching is one of the most productive and precise metal-cutting operations per formed today. Its also one of the most
misunderstood.
Broaching resembles planing or shaping, in that the broach tool
presents a sharp cutting edge to the workpiece and moves across
it, removing a predetermined amount of material. What primarily distinguishes broaching from other metal-cutting operations is the tooling used. A broach combines roughing, semi-finishing, and finishing
teeth in a single line. Although many variations exist, the basic tool
is an axial, multi-toothed rod, bar, or plate.
Broachings strengths are that it produces parts at a high rate,
removes heavy amounts of stock, roughs and finishes in one pass,
and permits the machining of complex contours and simple shapes
alike.
Economical operation is another advantage of broaching. While
initial tool costs generally are higher than for other metal-cutting
operations, the cost per finished par t is lower because of the high
production rates broaching permits. Coupled with automatic or
semiautomatic par ts-handling equipment, unskilled or semiskilled
operators can be employed, fur ther reducing operating costs.
Broaches also make shallow cuts and per form finish operations, often yielding smoother sur faces than can be attained with
other metal-removal processes. Some broaches have burnishing
sections that impar t almost any finish desired, thereby eliminating the need for grinding. In terms of productivity, repeatability,
accuracy, and sur face finish, broaching surpasses milling in any
one plane of a workpiece.
There are two basic types of broaches: sur face (external), and
internal. Sur face broaches cut on the outside of the workpiece,
while internal broaches enlarge or change the shape of an existing hole.
Surface Broaches
The simplest sur face broach is the slab broach, used for cutting flat
sur faces. Considered a general-purpose tool, it squares the ends
of parts or provides a reference sur face for additional broaching
or machining.
In applications involving hard sur faces or heavy stock removal,
free egress (or nibbling) broaches are employed. They have sets
of narrow roughing teeth positioned at a specific angle to the
centerline and quickly remove material. Full-width teeth follow the
roughing section and make semi-finishing and finishing cuts.
Slot broaches cut slots of various depths and widths. In operations requiring high production rates, slot broaching is faster and
more economical than milling. Two or more slots can be cut simultaneously with the proper tooling and fixtures. Its easy for standard
slotting broaches to cut slots in the ends or sides of a workpiece.
But thats not the case when cutting a slot along the parts length.
Often, heavier stock removal rates are involved that demand application of a longer broach.
Contour broaches cut concave, convex, cam-shaped, contoured,
and irregular sur faces to extremely close tolerances. Broaching
these sur faces requires that they be parallel and not present
obstructions in the broachs path.
Manufacturers of turbine engines often use dovetail (or pine
tree) broaches to create special forms in the compressor wheels
that hold blades in turbine discs. This sort of broaching usually involves multiple passes, due to the heavy amount of stock
32
GEAR SOLUTIONS
MARCH 2007
removed and the complex forms involved.

Pot broaches cut precision external forms
such as involute spur gears, splines, slots,
and special tooth forms. Pot broaching
allows the task to be per formed in a single
pass, making it an economical, high-production process. It has replaced hobbing and
shaping in the manufacture of many types of
external gears. During pot broaching, parts
are pushed or pulled through the bore of the
pot-broach holder.
Straddle broaches incorporate two separate slab-broach inserts to cut similar (or
identical) parallel sur faces on opposite
sides of the workpiece in one pass. Straddle
broachings advantage is that it maintains
a more precise dimensional relationship
between the two sides than would be possible with separate passes.
Internal Broaches
The round-hole broach is the simplest of the
internal broaches. It produces close-tolerance parts and smooth sur face finishes in
high-production applications. The round-hole
broach has a series of teeth that fully encircle the tool. Each tooth cuts on its entire
outer edge. When broaching ductile materials, round-hole broaches that incorporate
chipbreakers are required. They effectively
break the stringy chips that form so they fall
off the broach, itself.
A variety of hole shapes can be broached
besides round ones. Internal broaches cut
square, rectangular, octagonal, and hexagonal holes, as well as any other internal
shape. All thats required is the proper
starting hole for inserting the tool.
One of the most common internal broaches is the keyway broach, which resembles a
slot broach. A fixture called a horn usually
supports the broach, locating the part in the
hole where the keyway is to be cut.
To cut internal gear forms, an internal
gear broach is used. Its tooth pattern gradually nibbles away at the workpieces internal sur face, generating the desired gear
profile. A full-form finishing broach may be
needed to ensure accuracy and provide the
optimum sur face finish.
Broaching gun barrel bores necessitates
a rifling broach. This special tool is ver y long
so it can traverse the barrels full length. It
has relatively few teeth, as barrel grooves
are only a few thousandths of an inch
deep. The broach machine pulls the broach

through the bore while simultaneously rotating it to produce the spiral rifling pattern.
In some spline broaching applications,
the pitch diameter must be precisely concentric with the parts minor diameter. A
concentricity broach ensures this because
it has a full-form finishing section possessing alternating round and spline teeth that
shave the minor diameter and spline form.
Cutting splines in thin-walled parts is
always a problem. During the operation the
walls expand with the broachs passage but
then spring back, leaving improperly cut
splines. A cut-and-recut broach solves the
problem. It has a breathing area behind
the front cutting section that prevents part
shrinkage. The front of the tool cuts the
spline, than another cutting section at the
broachs end recuts it to precise tolerances.
Horizontal vs. Vertical Machines

The two most important factors to consider
when selecting a broaching machine are the
type of broach required for the application
and the number of parts to be produced.
MARCH 2007
GEAR SOLUTIONS
33
Machine size is determined by broach

length, how much force will be exerted on
the tool, whether its a push- or pull-broaching operation, and available floor space.
Horizontal machines are utilized primarily
for pull-through applications. One-way (cutting in one direction) and two-way (cutting in
both directions) models are available.
The automotive industr y makes extensive
use of large horizontal sur face-broaching
machines to remove heavy amounts of

stock. These machines cut sur faces on
large parts such as cast engine blocks, cylinder heads, manifolds, and bearing clusters.
With carbide inserts, stock-removal rates of
1/4 or more are possible.
In the past most broaching was done on
horizontal machines, but today they represent
just 10 percent of all the broaching machines
purchased. Vertical broaching machines have
become more popular because they take up

less space. This is an important consideration in plants where floor space is at a
premium.
A drawback to vertical machines, though,
is that they require a higher ceiling than horizontal models. In plants with low ceilings horizontal machines are still used, and they also
find use as special, low-profile equipment for
transfer lines and short-run applications.
Vertical machines typically are used for surface broaching. In operation either the broach
tool passes over the workpiece, or it remains
stationary while the part moves.
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34
GEAR SOLUTIONS
MARCH 2007
Almost any metal alloy is broachable, including soft materials such as brass, bronze, and
copper. Nonmetallic materialsgraphite, hard
rubber, wood, composites, and certain plasticscan also be successfully broached.
Free-machining materials are easier to
broach than tough, hard ones. In steels,
machinability is closely related to hardness.
Steels with hardness of Rc 10 to 30 are
excellent candidates for broaching, with those
in the Rc 16 to 24 range having the ideal
hardness. Usually, steels harder than Rc 35
dull broach teeth too quickly, forcing frequent
tool changes and regrinds. Cast and malleable irons allow more stock to be removed
per tooth than steels, as do brass and bronze.
Caution should be exercised when determining stock removal rates. Too heavy a cut will
cause the broach to overload.
Broach hook angles vary between 0-degrees
and 20-degrees+, depending on workpiece
ductility. Brittle materials such as cast iron
require a smaller hook angle, usually five
degrees to 10 degrees. The softer alloys of
aluminum and rolled steel pose special problems because they may adhere to the broach
teeth during cutting. This can be controlled
with proper sharpening, the right cutting fluid,
adjustment of the cutting speed, and altering
the step per tooth and tool geometry.
Each broaching operation is different, but

there are five areas in which broaching excels:
on parallel, multiple surfaces; when fast cutting is needed; automated operations; large
production runs; and tough materials. The
examples of typical broaching applications
that follow illustrate broachings versatility.
Figure 1 shows an outer gear form that
was pot broached. There are 31 teeth on the
diameter and the depth of cut of .156. The

part is used in a transmission for locating
clutch plates.
FIGURE 1
Figure 2 shows another example of pot

broaching on various transmission parts.
Each part has been broached using a pushup type broaching machine that loads the
part under the pot broach tools and pushes it
up through the pot. All of the splines or gear
teeth are cut at the same time around the
periphery. The part is completed in one pass
on the outside diameter form. Typically, this
operation will produce from 120 to 240 parts
per hour.
FIGURE 2
Figure 3 shows the cam form for a couple of

outer race parts in the transmission or drive
mechanisms for an automotive manufacturer.
Again, these parts were pot broached so that
all the cam forms are completed in one operation. The difficulty in broaching these types of
forms is the inherent cutting force that tends
to turn the part as it is being broached. With
the proper design of the tools, this situation
is controlled and the proper form is broached
equally spaced around the part.
FIGURE 3
Figure 4 shows parts that have been internally broached to various gear forms. Both are
transmission parts used by the automotive
CONTINUED ON PG. 50 >
MARCH 2007
GEAR SOLUTIONS
35
36
GEAR SOLUTIONS
MARCH 2007
earboxes are one of the most widely used types of industrial equipment in the
world. They are used as vital power transmission sources for nearly every kind
of business operating in the broader industrial market sector. Today, as industrial
gearbox applications continue to become more advanced, manufacturers are
responding by producing an increasingly wide range of gearbox designs to meet their
customers evolving needs. Advancements in gearbox technology, especially enclosed
gearboxes, have allowed designers to decrease the overall size of a gearbox while maintaining the same amount of power transmission capability. These types of improvements
result in systems that place much higher demands on lubricants.
So, how can customers ensure they are purchasing a lubricant that will help maximize the life of critical gearbox equipment? This article will describe important trends in
gearbox design and offer insightful tips that can help any plant manager, maintenance
professional, or purchasing agent make an informed decision in selecting the best gear
oil for the needs of their business.
Gearbox Design Changes: The Past 10 Years
By Jeff Biamonte
and Tim Nadasd
i, Ph.D.
In recent years, gearbox technology has become significantly more advanced.

Specifically, manufacturers have focused on developing systems that are more compact,
more efficient, and deliver higher load capacities. These newer units offer significant
advantages in terms of delivering better performance, and their reduced size
ensures they occupy less space in a plant.
That said, it is important to note that, compared to previous models,
these newer, high performance units typically require lubricants that offer
more comprehensive protection. Therefore, it is critical that companies
select a gear lubricant that can supply long-lasting protection for all gearbox components. What are some of the best ways to maximize gearbox
performance? Regardless of whether one has an older or newer gearbox
system, there are some key maintenance fundamentals that should be
followed.
First, it is strongly recommended that plant managers use a premium,
quality oil. Secondly, plant managers should work closely with their gearbox OEM and/or their lubricant supplier to proactively develop a preventive
maintenance schedule. Specifically, it is important to carry out at least annual
visual inspections, and also to conduct a thorough oil analysis on the oil each
quarter for the most critical gearboxes in their production systems.
Common Signs of Inadequate Gearbox Lubrication

Without inspection and oil analysis, noise, vibration, and oil leakage are often the first
signs of troubled gearbox operation. A common sign of inadequate gear lubrication that
is often overlookedbut is critically importantis micropitting.
Micropitting is surface fatigue that is mainly
observed in gears, but can also occur in rolling
element bearings. Micropitting causes destructive
wear that can occur within the first few hours of
operation. If left uncontrolled, micropitting can lead
to a reduction in gear tooth accuracy, and even gear
breakage.
Micropitting is not a new phenomenon. However,
it is much more prominent with the increase in the
power density of gearboxes, and the subsequent
increased use of case hardened gears (carburized,
nitride, induction and flame hardened). Although
a number of factors can affect the development
of micropitting, it is directly related to the surface
roughness and hardness of gears and bearings.
The surface roughness is usually due to asperities left from the finishing process.
The generally accepted theory for micropitting is that, as two asperities from oppo-
By choosing the proper lubricant,

gearbox performance is improved.
Read on to learn about ExxonMobils
special formulation for gearbox

applications.
MARCH 2007
GEAR SOLUTIONS
37
site surfaces collide, they each deform elastically and/or plastically, leading to metal fatigue
beneath the asperity. Micropitting on gears may
not only lead to problems with gears, but to
bearings and seals as well. The main concern
with micropitting is that this wear, which is often
overlooked, can cause the shape of the gear
teeth to change.
Preventing Micropitting
The selection of the appropriate viscosity grade
is the first and most important step in choosing
a lubricant for any application. To find the right
viscosity, it is good practice to consult the OEM
manual as a starting point. However, many
OEM-suggested guidelines do not necessarily
consider factors that come into play if the gearbox is operating under extreme conditions, such
as heavy loads and high temperatures. Even

under extreme conditions, simply increasing the
ISO viscosity grade of the oil is not necessarily
preferred. Instead, selecting a lubricant with a
higher viscosity index, lower traction coefficient,
or both should be considered. A higher viscosity
index can provide a thicker lubricant film under
operating conditions. A lower traction coefficient
can help to reduce surface fatigue.
Due to the high viscosity index and low traction coefficient, moving to a synthetic gear oil
can help control micropitting. In addition to
viscosity and traction, the additive chemistry in
finished lubricants can have a dramatic effect
on micropitting performance.
For instance, it has been shown that certain
additives, especially conventional extreme pressure additives, can have a negative effect on
micropitting performance. Choosing an oil that
is specifically designed to give micropitting
protection will not only reduce the risk of micropitting, but it will often deliver other benefits,
including enhancing the durability and performance of a gearbox system and its most critical
components.
Mobilgear 600 XP
In November of 2006, ExxonMobil announced
the worldwide introduction of its Mobilgear 600
XP Series; a family of premium gear oils that
are formulated to deliver exceptional, long-lasting protection for industrial gearboxes. With its
advanced and balanced formulation, Mobilgear
600 XP delivers exceptional performance over
the long haul, exceeding the industrys most
demanding specifications, such as Flender BA
Table 7300 A, DIN 51517 Part 3 and AGMA
9005 E02. It is formulated to reduce wear and
enhance the performance of all critical gearbox
componentsincluding gears, bearings, and
seals. (Please see micropitting test on the following page.)
By providing exceptional wear protection, this
new series of gear oils help control micropitting
and other forms of gear wear. Its balanced formulation improves bearing and corrosion protection, while remaining compatible with commonly
used gearbox seal materials. Furthermore, it is
designed to significantly reduce the formation of
lubricant degradation byproducts that often lead
to frequent oil changes.
ABOUT THE AUTHORS:

Jeff Biamonte is global lubricants marketing advisor and Tim Nadasdi, Ph.D., is product technical
advisor for ExxonMobil Lubricants & Specialties.
To learn more go to [www.exxonmobil.com].
38
GEAR SOLUTIONS
MARCH 2007
Gear Teeth After Micropitting Test:

The boxed areas show micropitting formation. Test results
in Fig. 1 show that Mobilgear 600 XP provides superior
micropitting protection over generic oils.
FIGURE 1: 12 PERCENT
AVERAGE MICROPITTING
COVERAGE ON TEETH
(ROOT ONLY)
MOBILGEAR 600 XP
FIGURE 2: 49 PERCENT
AVERAGE MICROPITTING
COVERAGE ON TEETH
(ROOT AND ADDENDUM)
Typical Industrial Gear Oil not designed

to protect agains micropitting
FIGURE 3: CHOOSING THE PROPER LUBRICANT HELPS GEAR

TEETH RETAIN THEIR INTEGRITY
MARCH 2007
GEAR SOLUTIONS
39
CASE
STUDY
By Ross Wegr yn-Jones
COMPANY: Advent Tool & Manufacturing, Inc.

CUSTOMER: MESCO
40
GEAR SOLUTIONS
MARCH 2007
A New Tool forPrototype and Production

The following case study describes the development of an
involute spline form milling tool for prototype and production
applications in standard CNC milling machines.
WELL
known for its specialization in indexable and solid carbide thread and form
milling tools, Advent Tool and Manufacturing
has developed an involute spline form milling
tool for prototype and production applications
for use in standard CNC milling machines.
Utilizing our patented inser t locking and locating system on a standard shell threadmilling platform, James Har tfordvice president
and general managerground a three-tooth
form in standard Advent Tool threadmilling
inser t blanks to accurately duplicate the form
required on an end users spline shaft form.

The hurdle on this particular application was
twofold, Hartford says, getting the tooth geometry planned out per the given workpiece diameter
and finding the right application and consumer to
prove out our prototypes.
As it was, Advent Tool distributor Muenz/
Engineered Sales Company (MESCO) had the right
application. Paul Dunn of MESCO had an end user
with an ANSI B92.1-1970 1-1/4 pitch diameter,
30-tooth spline form at 24/48 pitch and 2-3/4
in length. This end user needed to generate an
extremely accurate spline form on their stainless
steel shaft with a very fine surface finish require-
MARCH 2007
GEAR SOLUTIONS
41
ment. With the workpiece requirement being of stainless steel, the

customers options to generate this form were limited, to say the least.
Finding the right manufacturer who could partner with us and our customer on this engineered application was the key, Dunn says. Advent
Tool was the right kind of company with the right kind of tool designs,
and they were willing to put their expertise to work.
Advent Tool has had
vast experience in thread
and form milling a variety of forms in stainless
steels. We knew that our
standard form milling
platform was more than
adequate for the project at hand. With some
development time we
completed the inserts,
and success was achieved immediately with the end user in terms of
cycle time and tool life; not to mention a relatively minimal investment
in specialized spline hobbing equipment and tooling.
A typical theme of spline milling applications that we are seeing
lately is the need to reduce cycle time and complexity. An application
for spline milling was recently quoted and a tool build is in progress
for a Tier I automotive supplier that typically took the shaft offline to
be hobbed on traditional high speed steel spline hobbing equipment
and then brought back to the original CNC milling machine for the final
operation. Using the Advent indexable spline milling tool to generate
the spline form, and foregoing the offline process, the manufacturer
was able to reduce cycle time significantly. Not measured, but certainly
implied, were quality and time saving gains by not having to find the
part again using the aforementioned offline process.
The Advent indexable tool design utilizes completely ground tool
bodies and locating devices to hold carbide inserts in an exact position axially and radially. This unique, patented tool
design minimizes uneven chip loads amongst the
inserts while cutting the workpiece. This precision,
in turn, leads to longer tool life, faster speeds and
feeds, and more accurate form generation in the
workpiece. Coolant through is standard with Advent
Tools, with coolant directed between the flutes or
right at the cutting tool interface. As you can imagine in an aerospace part, the thread forms must be
perfect. Advents tool design is known for accurate,
repeatable thread generation in the aerospace,
commercial, and automotive industries. This spline form application
represents the cutting edge of Advents form milling pursuits to date.
The application listed here has utilized standard Advent threadmilling bodies, with specialized inserts. Advent Tool has recently had calls
for some coarser pitches and larger pitch diameters with finer pitches.
In these cases, standard milling bodies were not used, but the same
concepts with a special body applied. H13 tool steel was used, and,
like their coarse pitch thread milling cousins, bodies were modified and
made to suit taller inserts with greater minor/major diameters.
Initial internal tests conducted by Advent to provide proof-of-concept
Finding the right manufacturer to

partner with us and our customer was
the key, and Advent Tool was the right
company with the right tool designs.
Maximum module up to 30mm (D.P. 0.85) spiral bevel gear,

zero bevel gear and hypoid gear by generating method.
JINGCHENG suggests
YH6012 NC spiral bevel gear generator series
n Products range:
Spiral bevel gear generator series (D.P. 10-0.85, diameter:5-63)
Gear pointing machine series (diameter:1.2-15.7)
Spiral bevel gear lapping machine series (diameter:19.7)
Auxiliary machine series
NC gear cutter sharpener
Manual gear tester
NC spiral bevel gear tester
All products have one year warranty. As part of our commitment to providing
excellent customer service, we guarantee to contact you within 24 hours after a
problem is brought to our attention. We welcome your business around the world.
TIANJIN JINGCHENG MACHINE TOOL MFG Co., Ltd.

USA Representative office:
Tel: 001-714-972-8364 Cell: 001-714-244-8808
Email: Hou44Liu@hotmail.com or Harold.Liu@ihhioc.com
Contact: HAROLD LIU
Germany Agency:
Contact Person: Lanny Chen
Address: TopBox C2207, No. 69 West Beichen Road
Chaoyang District, Beijing 100029, China
Telephone: 0086-10-58772450
Email: Lanny@esbchina.com
Website: http://www.eisenbeiss.com
Fax: 0086-10-58772480
Brazil Agency:
Contact Person: Fernando B. Gandara Mendes
Website: www.ghc-equipamentos.com.br
Telephone/Fax: 55114702-4433
Email: Fernando@ghc-equipamentos.com.br
Cell: 55119938-6131
Headquarters:
Add: 10, Lixin Road, Dongli Economy Development Zone TIANJIN P.R. CHINA
Tel: 0086-22-24981172 Fax: 0086-22-24981170
Web: http://tj-jcmt.com Email: jingcheng@tj-jcmt.com
Post code: 300300
42
GEAR SOLUTIONS
MARCH 2007
in house were performed on H13 tool steel, and the subsequent

results were impressive. In a standard CAT 40 class vertical machining
center with a fourth-axis rotary table, two passes were needed in each
three tooth cutting pass with this eight-flute shell mill tool. The process
took a total of 20 passes to complete the part, and 880 surface feet
per minute, 1600 rotations per minute, 40 inches per minute feed, and
.003 chipload per tooth were the parameters for the roughing pass.
1700SFPM, 3000RPM, 30IPM, and .0015 chipload per tooth were
achieved for the finishing pass.
Naturally, this is not going to be competitive with spline rolling in
terms of cycle time. However, as it is with most things in life, each
choice has its own limitations. Advent tools care not about spline
length. Likewise, the form and the surface finish can be more tightly
controlled using the Advent system. As long as there are no shoulder
interferences (there are options available if this is the case), the milling tools are made to mill workpieces, regardless of workpiece length.
Coarse or fine pitches do not matter as much with the Advent system;
the inserts are built to suit, and bodies can be made to suit if needed.
For that matter, assuming a standard tool body, lead times for new
spline milling tools are relatively shortabout four weeks from print
approval. While other processes have their ins and outs, the typical
Advent consumer already knows the parameters of milling.

Threads are just defined forms, as specified by ANSI and ISO, and
the appropriate tools are made and kept on the shelf, in stock, at
Advents headquarters. Coatings are applied to suit the application,
but are typically stocked in either uncoated, TiN, or TiAlN varieties.
Serrations on (previously) broached parts, front and back chamfers, Oring/snap ring grooves, and even inserts to generate a defined surface
finish on mating pipe flange parts have been successful applications.
Advent Tool has also successfully designed and built complete blueprint specials for other forms that customers need as well, such as a
one-pitch buttress form.
There have been multitudes of spline milling applications that Advent
has completed since MESCOs original application. Advent inserts are
typically ground to suit, but the bodies are almost always standards.
What are we working on now? Since completing several spline forms
on shafts, the natural progression would be ID spline push broaching. Again, as the design is made specific to the workpiece diameter,
Advent does have some initial tool and insert designs that are in the
working prototype stage. Pushing three teeth into the workpiece at a
time, several strokes are required to generate the full form, but the
main advantage has proven to be accuracy, not speed.
ABOUT THE AUTHOR:

Ross Wegryn-Jones is national sales manager for Advent Tool and Manufacturing, Inc.
He can be reached at (800) 847-3234, (847) 549-9737, or rosswjones@advent-threadmill.com. Go online to [www.advent-threadmill.com].
MARCH 2007
GEAR SOLUTIONS
43
MACHINERY
featuredSUPPLIERS:
Midwest Gear Corporation Ref #100
Phone: 330-425-4419 Fax: 330-425-8600
Email: sales@mwgear.com
Website: www.mwgear.com
Contact Gear Solutions at

800-366-2185 to list your machinery.
BARBER-COLMAN 6-5, S/N 396, 66 Wet w/Auto Dress & Sparkout REF#104
PFAUTER #P-750R, 8" Dia Rotors, 35" Face, 12", MINT!! 82 REF#103
BARBER-COLMAN 6-5, S/N 433, 69 Wet w/Auto Dress & Sparkout REF#104
PFAUTER #P-900, 2 DP, 36 Dia, 15 Face, Tailstock, 60 REF#103
BARBER-COLMAN 10-12, S/N 643R83, Wet w/Auto Dress, PC
RPM #AD-616, 6 Dia, 16 Face, 16 DP, (3) Thread, NEW REF#103
Control, Fact Reb 83 REF#104
STANKO #5A-342, 100-160 Dia, 34 Face, .84 DP, Beautiful Piece, 80 REF#103
WOLF #GH20-11, 20 Dia, 11 Face, 3.2 DP, 98 REF#103
GEAR HOBBERS/CUTTERS
WOLF #GH32-11, 32 Dia, 11 Face, 2.5 DP, 98 REF#103
KOEPFER #150, 6 Dia, Refurbished w/Accessories REF#101
BARBER-COLMAN 2 1/2 -4, S/N 119, 62 Hi-Production Spur Gear REF#104
KOPEFER #151, 6 Dia, Refurbished w/Accessories REF#101
BARBER-COLMAN 6-10 SYKES, Triple Thrd w/Lever Operated Collet Assy REF#104
KOPEFER # 170, 5.1 Dia, Refurbished, w/Accessories REF#101
BARBER-COLMAN 6-10 B&C Ltd, S/N 8079, Triple Thrd REF#104
PFAUTER #RS00S, 8/10 Dia, 6 DP, Diff REF#101
BARBER-COLMAN 6-10, S/N 4626, 57 Triple Thrd 3 Hob Slide REF#104
LIEBHERR #L-301, 12 Dia, 2-Cut, Crowning REF#101
BARBER-COLMAN 6-10, S/N 4659R, 56 Triple Thrd Adj Ctr Assy REF#104
CLEVELAND #CR-300, 12 Dia, Crowning, 2-Cut, New REF#101
BARBER-COLMAN 6-10, S/N 4665, 57 Fine Pitch Prec Triple Thrd REF#104
PFAUTER # P-400, 16 Dia, Vertical Universal, High Tailstock REF#101
BARBER-COLMAN 6-10, S/N 4701, 58 Triple Thrd w/Power Down Feed REF#104
PFAUTER #P-403, 18 Dia, Auto-2-Cut, New 79 REF#101
BARBER-COLMAN 6-10 M/C, S/N 4755, 59 Triple Thrd w/MC Conversion REF#104
R. P. Machine Enterprises, Inc. Ref #103

Phone: 704-872-8888 Fax #:704-872-5777
Email: sales@rpmachine.com
Website: www.rpmachine.com
LIEBHERR #L-901, 36 Dia, Crowning, Auto-2-Cut, Diff, Yr 74 REF#101
BARBER-COLMAN 6-10 Multicycle, S/N 4778R87, 60 (87 Rebuild),
G&E #96H, 100 Dia, 1 DP, Crowning, New 72 REF#101
Sgl Thrd Hi-Spd REF#104
BARBER COLMAN #3, 6 Dia REF#101
BARBER-COLMAN 6-10 M/C, S/N 4913, 63 Triple Thrd w/90 Deg Hob Slide REF#104
BARBER COLMAN #16-16, 16 Dia REF#101
BARBER-COLMAN 6-10 Multicycle, S/N 5055, 66 Triple Thrd, 800 RPM REF#104
Repair Parts, Inc. Ref #104

Phone: 815-968-4499 Fax #:815-968-4694
Email: rpi@repair-parts-inc.com
Website: www.repair-parts-inc.com
BARBER COLMAN #14-15, 14 Dia, Series A-2, Shift, 2-Start REF#101
BARBER-COLMAN 6-10, S/N 5141, 67 Triple Thrd w/Prec Hob Shift REF#104
BARBER COLMAN #14-15, 14 Dia, 4-Start Index, Chucking REF#101
BARBER-COLMAN 6-10 Multicycle, S/N 5148, 68 Triple Thrd, 800 RPM REF#104
BARBER COLMAN #16-36, 16 Dia, w/Differential REF#101
BARBER-COLMAN 6-10 Multicycle, S/N 5259, 75 Triple Thrd w/Auto Hob Shift REF#104
BARBER COLMAN Multi-Cycle #16-36, 16 Dia, w/shift C-Frame REF#101
BARBER-COLMAN 6-10, S/N 5353, 77 Triple Thrd w/3 Hob Slide, 800 RPM REF#104
TOS OF-16, 60 Dia, Auxiliary Work-table, Change Gears REF#101
BARBER-COLMAN 6-10, S/N 5394, 81 Fine Pitch Triple Thrd w/Dwell & Hob Rev REF#104
BARBER-COLMAN #14-15, 14 Dia, 15 Face, 1 to 4 Start Worm, Several REF#103
BARBER-COLMAN 6-16 M/C, S/N 5238, 70 Triple Thrd, Recon 02 REF#104
BARBER-COLMAN #14-30, 14 Axis, 30 Dia, 3.5 DP REF#103
BARBER-COLMAN 6-10, S/N 5407, 82 Auto w/PLC Control REF#104
BARBER-COLMAN #16-16, Multi-Cycle, Dual Thread Worm, Downfeed REF#103
BARBER-COLMAN DHM, S/N 105, 42 Double Thrd REF#104
BARBER-COLMAN #16-36, 24 Dia, C-Frame Style, 4 1/8 Bore REF#103
BARBER-COLMAN 14-15, S/N 635R, 53 Dbl Thrd, Fact Reb REF#104
BARBER-COLMAN #16-56, 16 Dia, 56 Face, Differential REF#103
BARBER-COLMAN 14-15, S/N 745, 55 Dbl Thrd w/Dwell REF#104
BARBER-COLMAN #2.5-4, 2.5 Dia, 2.25 Face, Precision Machine REF#103
BARBER-COLMAN 14-15 Dual Fd, S/N 938, 62 Dbl Thrd, Comp Reco REF#104
BARBER-COLMAN #22-15, 22 Dia, 14 Face, Differential REF#103
BARBER-COLMAN 14-15, S/N 1055, 65 Dbl Thrd w/New Hyd Sys REF#104
BARBER-COLMAN #3 (6-10), Single & Triple Tread Worm Ref # Several REF#103
BARBER-COLMAN 14-15, S/N 1131, 66 Dbl Thrd w/Hyd Tailctr REF#104
BARBER-COLMAN #6-16, 6 Start Worm, Downfeed, Hyd. Clamping REF#103
BARBER-COLMAN 14-15 Dual Fd, S/N 1261, 67 Dbl Thrd w/Hyd Live Ctr REF#104
G&E #24H Universal Head, Infeed, Tailstock, Differential, 50s REF#103
BARBER-COLMAN 14-15 Dbl Cut, S/N 1278, 68 Dbl Thrd w/4-1/8 Bore REF#104
G&E #36HWD, Differential, Excellent Condition REF#103
BARBER-COLMAN 14-30 Dual Fd, S/N 1371, 71 4-Thrd w/Sizing Cycle REF#104
G&E #48HWD, Differential, Excellent Condition REF#103
BARBER-COLMAN 22-15, S/N 923, 62 Dbl Thrd, Dbl Cut REF#104
G&E #72H, 72" Dia, 1.5 DP, 24" Face, Diff, Infeed REF#103
BARBER-COLMAN 16-11, S/N 184, 50 Dbl Thrd w/Vert DRO REF#104
G&E #96H, High Stanchion, Differential, Infeed REF#103
BARBER-COLMAN AHM, S/N 1896, 42 Sgl Thrd w/3 Jaw Chuck REF#104
HAMAI #120, 4.8 Dia, 4 Face, 12 DP, 70 REF#103
BARBER-COLMAN 16-16, S/N 2745, 51 Sgl Thrd w/90 Deg Hd REF#104
KOEPFER #135, Horiz, Loader, 3 Dia, 3 Face, 25 DP, 60 REF#103
BARBER-COLMAN 16-16, S/N 3171, 53 Dbl Thrd, Spanish Nameplates REF#104
LIEBHERR #L-301, 12 Dia, 9 Face, 4 DP, 74 REF#103
BARBER-COLMAN 16-16, S/N 3580, 59 Dbl Thrd w/Diff & Auto Hobshift REF#104
LIEBHERR #L-401, 16 Dia, 8 Face, 3 DP, 70s REF#103
BARBER-COLMAN 16-16 Multicycle, S/N 3641, 60 Dbl Thrd w/Diff REF#104
LIEBHERR #L-402, 16 Cap, 2-Cut Cycle, Crowning, 77 REF#103
BARBER-COLMAN 16-16, S/N 3660, 57 Sgl Thrd REF#104
LIEBHERR #L-650, 26" Dia Cap, 14.5" Face, 2.5 DP, New 70s REF#103
BARBER-COLMAN 16-16, S/N 4136, Dbl Thrd, C Style End Brace w/Diff REF#104
LIEBHERR #L-652, 25" Dia Cap, 19.7" Face, 2 DP, Well-Equipped REF#103
BARBER-COLMAN 16-16 Multicycle, S/N 4170, Dbl Thrd w/Jump Cut Cycle C Style REF#104
LIEBHERR #L-901, 35" Dia, 2.5 DP, 2-Cut Cycle, Univ Hob Head REF#103
BARBER-COLMAN 16-16, S/N 4473, 73 4-Thrd w/Workclamp Cyl C Style REF#104
LIEBHERR #L-902, 36" Dia, 25" Face, 2 DP, Crowning, 78 REF#103
BARBER-COLMAN 16-16 Multicycle, S/N 4520, 75 Dbl Thrd w/Gooseneck Slide REF#104
MODUL #ZFZW 800, 29.8 Dia, 16.25 Face, 2.5 DP Crowing, 2-Cut REF#103
BARBER-COLMAN 16-16 Multicycle, S/N 4631, 79 C Style End Brace, 4W Adj Ctr REF#104
OVERTON #HD-400, 15.7 Dia, 12 Face, 3 DP, New 88 REF#103
BARBER-COLMAN AHM (36), S/N 1152, 42 Dbl Thrd REF#104
PFAUTER #P-400, 3 DP, 16" Dia, 11" Face, Auto-Cycle, 65 REF#103
BARBER-COLMAN 16-36, S/N 4090, 66 Dbl Thrd, C Style End Brace REF#104
PFAUTER #P-630, 24 Cap, 2-Cut Cycle, Crowning, 78 REF#103
BARBER-COLMAN 16-36 Multicycle, S/N 4232, 68 Dbl Thrd C Style End Brace w/Diff REF#104
Mohawk Machinery, Inc. Ref #101

Phone: 800-543-7696 Fax: 513-771-5120
Email: sales@mohawkmachinery.com
Website: www.mohawkmachinery.com
New England Gear Ref #102
Phone: 860-223-7778 Fax #:860-223-7776
Email: jeff@newenglandgear.com
Website: www.newenglandgear.com
GEAR ACCESSORIES, PARTS & TOOLING

FELLOWS Model #10-4/10-2, All Parts Available REF#102
Tilt Tables for 10-2/10-4, Qty 2 REF#102
GEAR HOBBERS/CUTTERS CNC
PFAUTER #PE-150, 6 Dia, 6-Axis CNC, New 86 REF#101
LIEBHERR #LC-152, 6/8 Dia, 7-Axis CNC w/Automation, New 90 REF#101
PFAUTER #PA-320, 14 Dia, 6-Axis, Rebuilt/Retrofit 06 REF#101
G&E #96H, 100 Dia, .75 DP, CNC Universal REF#101
G&E #96H, CNC, Gasher/Hobber, New 05 REF#103
G&E #120H, CNC, Gasher/Hobber, Twin Stanchion, 1/2 DP, 42 Face, 94 REF#103
G&E #160H, CNC, Gasher/Hobber, New 05 REF#103
GLEASON PHOENIX #200GH, 6-Axis CNC, 7.87" Dia, 7.8 DP REF#103
HAMAI 60H, CNC 4-Axis, 3.5" OD, 9" Face, 12 DP, New 89 REF#103
LIEBHERR #LC-252 CNC, 6-Axis, 10 Dia, 10 Face, 4 DP, 77 REF#103
LIEBHERR #LC-255 CNC, 6-Axis, 10 Dia, 10 Face, 4 DP, 87 REF#103
LIEBHERR #L-1202 6-Axis CNC, 49 Dia, 24 Face, 1.2 DP, 78 REF#103
MITSUBISHI #GA-40, 5-Axis, 16 Dia, 10 Face, w/Fanuc, 86 REF#103
PFAUTER #P-250H, 6-Axis, 11.81 Dia, Fanuc O Control, New 85 REF#103
PFAUTER #PE-125H, 6-Axis, 5" Dia, 8.5 DP, 9.5" Max Swing, 88 REF#103
PFAUTER #PE-150, 6-Axis CNC, 6 Dia, 5 DP, 6 Face, Fanuc 18MI REF#103
PFAUTER #PA-320, 6-Axis CNC, 13 Dia, 3 DP, 10 Face, New 80 REF#103
PFAUTER #PE-500, 6-Axis CNC Gear Hobber, 13.78" Dia, 3 DP REF#103
RP MACHINE #SH-150/750, 4-Axis CNC Spline Hobber, New 05 REF#103
SYKES #H160, 4-Axis CNC Hobber, 6 Dia, All the Features, 93 REF#103
BARBER-COLMAN 2 1/2-2, S/N 16, 66 Wet w/Auto Feed REF#104
BARBER-COLMAN 6-5, S/N 110R, 55 Wet w/Auto Dress & Sparkout REF#104
MARCH 2007
GEAR SOLUTIONS
45
BARBER-COLMAN 16-56, S/N 3136R84, 53 (Reb 84), Dbl Thrd REF#104
FELLOWS #61, #6A, #61A, #645A, From 18-35 Dia, 0-12 Risers REF#103
BARBER-COLMAN 10-20, S/N 6700045890, 76 Dbl Thrd w/2 Cut Cycle REF#104
FELLOWS #7, #7A, #715 Etc, 7 Dia, 0-12 Risers, Several Avail REF#103
GEAR PINION HOBBERS & SPLINE MILLERS
FELLOWS #8AGS Vert Gear Shaper, 8 Dia, 2 Face, 6-7 DP REF#103

FELLOWS #10-2, 10 Dia, 4 Face, 4 DP REF#103
DAVID BROWN, #P-40H, 40 Dia, 100 Face, 2 DP, New 70 REF#103
FELLOWS #10-4, 10 Dia, 4 Face, 4DP REF#103
FITCHBURG, 40 Dia, 73 Face REF#103
FELLOWS #20-4, 20 Dia, 4 Face, 4 DP, 70s REF#103
LEES BRADNER #SH, 8 Dia, 54 Face, 4 DP, 50 REF#103
FELLOWS #36-6, 36 Dia, 6 Face, 3 DP, 51-72 REF#103
HURTH #KF-32A 15 Dia, 59 Face, 67 REF#103
FELLOWS #120-8, 8 Stroke, Spur Guide, Rebuilt 1988, New Electrics REF#103
WANDERER #31M, 12 Dia, 118 Length, Hob Head Equipped REF#103
FELLOWS #200, 8 Stroke, 200 Dia Spur, Exc. Cond 1 DP, Rebuilt 88 REF#103
GEAR HOB & CUTTER SHARPENERS (incl CNC)
FELLOWS #Horiz Z Shaper, 6 Stroke, 17 Bore in Table, New 50s REF#103

LORENZ #LS-320, Tilt Shaper, 12 Dia, 2 Face, 4 DP, New 80s REF#103
BARBER COLMAN #2 1/2-2, 2.5 Dia, Straight Flute Hobs REF#101
LORENZ #LS-320, 12 Dia, 2 Face, 4 DP, New 88 REF#103
FELLOWS 6HCS, 6 Dia, Helical Shaper Cutter Sharpener REF#101
MAAG #SH-75C, Disc Control, 9 Stroke, Auto Stop, Exc, 65 REF#103
GLEASON 2JST Straight Bevel Coniflex Cutter Sharpener REF#101
MAAG #SH-100/140, 57 Dia., 12.6 Face, 2 DP, Internal Attachment REF#103
GLEASON 13 Universal Hypoid Bevel Cutter Sharpener REF#101
MAAG #SH-180/300, Ext. Generating/Int Gashing Heads, New 60s REF#103
ARTER #A-12, 12 Rotary Surface Grinder for Sharpening Sharper Cutters REF#103
MAAG #SH-250, 43 Dia., 26 Face, Crowning, New 74 REF#103
BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, 57 REF#103
GEAR DEBURRING/CHAMFERING/POINTING
BARBER-COLMAN 10-12, 10" Dia, 12" Length, Spark Out REF#103

FELLOWS #6SB, Helical Cutter Sharpener, 6 Dia, up to 50 Degrees REF#103
CROSS #75, 10 Dia REF#101
HEALD #22 Rotary, 13 Dia, 12 Chuck REF#103
REDIN #24, 28 Dia, CNC, Twin Spindle Deburring Mach, Yr 90 REF#101
KAPP #AS204GT, 10 Dia, Wet Grinding, CBN Wheels, 82 REF#103
REDIN #18, 20 Dia, Twin Spindle Deburring Mach REF#101
KAPP #AS-305T, 12 Dia, 28 Face, 1 DP, Mint Condition, New 80s REF#103
CROSS #50 Gear Tooth Chamferer, 18 Dia, Single Spindle REF#103
KLINGELNBERG #AGW-30A, 11 Dia, 16 Part Length, Straight & Spiral Gash REF#103
CROSS #54 Gear Tooth Chamferer, 30 Dia, 18 Face REF#103
KLINGELNBERG #AGW-231, Auto Hob Sharpener, 10" Dia, 74-80 REF#103
CROSS #55 Gear Tooth Chamferer, 18 Dia, 14 Face REF#103

CROSS #75 Gear Tooth Chamferer, 10 Dia, 10 Face, 52 REF#103
GEAR SHAPERS CNC
HURTH #ZK-7, 11 Max Dia, Twin Spindle Gear Chamferer REF#103
36 Shapers, 14 Throat Risers, 53 of Swing, Qty 3 REF#102
RED RING #GCU-12, Gear Shaver, 12 Dia, Several REF#103
FELLOWS #10-4/10-2, Qty 150 REF#102
RED RING #GCY-18, Gear Honing Mach, 18 Dia, 6 Stroke REF#103
HYDROSTROKE #50-8, Qty 2 REF#102
RED RING #GCX-24, 3-24 Pitch Dia Crowning, Tailstock, Taper Att REF#103
HYDROSTROKE #20-8, Qty 5 REF#102
REDIN #18, 28 Dia, 2, 3, 4 Spindle, Deburrer/Chamfer, PLCs, Tilt Table REF#103
HYDROSTROKE #FS630-125, Qty 1 REF#102
REDIN #20D, 20 Dia, Twin Spindle, Deburrer/Chamfer REF#103
HYDROSTROKE #FS400-90, Qty 2 REF#102
SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14 Dia, 5 Face, 82 REF#103
FELLOWS #20-4, Qty 6 REF#102
SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10 Max Dia, (3) New 96 REF#103
FELLOWS #48-8Z, Qty 1 REF#102
WERA #MC6-150, CNC, Deburrer, Chamfering and Pointing, 8 Dia, New 88 REF#103
FELLOWS #10-2 & 10-4, 1 to 4-Axis CNC, 10 Dia, 2-4 Face, Rebuilt REF#103
GEAR HONERS
FELLOWS #10-4 One-Axis CNC (A/B), 10" Dia, 4" Face, 4 DP REF#103
FELLOWS #20-4, 4-Axis, 20 Int/Ext, Dia, 4 Face, New 70/03 REF#103
FASSLER #K-400 Internal Gear Honer, 12.6 Dia, 12 Stroke, NUM 1080 Control REF#103
FELLOWS #20-8, Hydrostroke 6-Axis CNC, 20" Dia, 8" Face, 3 DP REF#103
GEAR SHAVERS
FELLOWS #FS-180, 3-5 Axis, 7 Dia, 1.25 Face., 6 DP, New 88 REF#103
RED RING #GCY-12, 12 Dia, 9 Cutter-Head REF#101
LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#103
RED RING #GCU-12, 12 Dia, 9 Cutter-Head REF#101
LORENZ # LS-180, 4-Axis CNC, 11 OD, 2 Stroke, 5 DP REF#103
KANZAKI #GSF-400CNC5, CNC, 16 Dia, 10 Cutter-Head 90 REF#101
LORENZ #LS-424, 16.5" Max Dia, 5.4" Stroke, 90s REF#103
RED RING #GCU-18, 18 Dia, Crowning REF#101

RED RING #GCJ-36/60, 60 Dia, 12 Cutter-Head REF#101
GEAR SHAPERS
GEAR GENERATORS, STRAIGHT BEVEL
FELLOWS #3, 3 Dia, Fine Pitch, w/Change Gears REF#101
FARREL #5B, 61 Dia, 30 Guide, 18 Face, New 50s REF#103

FARREL #5T, 61 Dia, 30 Guide, 24 Face, 2 DP REF#103
GEAR GRINDERS CNC
HOEFLER #H-650/800, 36 Dia, CNC w/On-Board Inspection, New 98 REF#101
GLEASON # 130, 36 Max Dia, CNC Curvic Cplg, Comp Reb REF#101
HOFLER/NOVA, #650/800, 25 Dia, 21 Face, 1.4 DP, New 98 REF#103
OPAL #50 CNC Form Grinder, 20.5" Dia, 24.8" Face, 98 REF#103
OPAL #420 CNC Form Grinder, 16 Dia, 14 Face, 2 DP, New 93 REF#103
OPAL #1200 CNC Form Grinder, 47 Dia, 25 Face, 1.5 DP, 97 REF#103
REISHAUER #RZ-801, 31 Dia, 11 Face, 3.5 DP, New 91 REF#103
GEAR GRINDERS
MAAG #HSS-30A, 11.8 Dia, Spur REF#101
REISHAUER #AZA-K, 13 Dia, SPA Diamond Disc, Taper Grinding New 79 REF#101
REISHAUER RZ-300E, 11.8 Dia, Diamond Disc Dresser, Shift New 85 REF#101
SHG-360 OKAMOTO, 14 Dia, FAESSLER DSA, Crowning, New 74 REF#101
DETROIT GEARGRIND GGI-16x3A Internal Gear Grinder REF#101
MICHIGAN DETROIT GG-10x24A, 10 Dia, Ext Gear & Spline Grinder REF#101
FELLOWS-REISHAUER #12, 12" OD, 6-3/4" Face, Dresser, Gears REF#103
HOFLER H2500/1200, 98 Dia, 47 Face, 8DP, 74, ISO 3-4 Quality REF#103
REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#103
REISHAUER #AZA & #AZA-K, 11 Dia, 3 DP, 7 Face, Exc Cond REF#103
REISHAUER ZB Gear Grinder, 27 5 Max Dia, 11 Face, Good Cond 70 REF#103
RED RING #SF-500 Int/Ext, 26 Dia, 30 Face, 2 DP, 88 REF#103
RED RING #SGJ-18, 18 Dia., 9 Face, Internal Attachment, New 78 REF#103
GEAR RACK MILLERS/SHAPERS
FELLOWS #3X36 Rack Shaper, 3 Face, 36 Face, 4 DP, Good Cond 60 REF#103
MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#103
SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, 80 REF#103
GEAR THREAD & WORM, MILLERS/GRINDERS
WMW HECKERT #ZFWVG, 10 Dia, 49 Length, 4, 99 REF#103
WMW HECKERT #ZFWG 250 X 2000, 19.6 Over Bed, 19.6 78.7 Hob Length
LEES BRADNER #HT 12"x 36" Thread Mill, 12" Dia, 36" Length REF#103
LEES BRADNER #LT 9"x 54" Thread Mill, 9" Dia, 54"Length REF#103
MIKRON #106-02, 1.5 Dia, 3-6 Length, Single Form Worm Cutter REF#103
J&L #12x45, Thread Grinder, 12 OD, 45 Length, Nice, 75 REF#103
REISHAUER #UL-900, 9 Dia, 18 Grinding Length, 80s REF#103
REISHAUER #US, 10 Dia, 36 Grinding Length, 46 B-C, 80 REF#103
WANDERER #31L x 3000, 8 Dia, 120 Length, 60s REF#103
FELLOWS #7125A, 7 Dia REF#101
GLEASON #710, 10 Dia, Coniflex REF#101
FELLOWS #4AGS, 7 Dia REF#101
GLEASON #14, 24 Dia, Coniflex w/gauges, gears REF#101
FELLOWS #10-4, 10 Dia, 4 Face REF#101
OERLIKON #K4A, 60/90 Dia w/Templates, Crowning, Gears REF#101
FELLOWS #10-2, 10Dia, 2 Face REF#101
GLEASON #12, Str Bev Gear Gen, 12 Cone, 3.5 Face, 50s REF#103
FELLOWS Z-Type Horizontal, 18 Dia, Change Gears, Nice REF#101
GLEASON #14 Coniflex Str Bev Gear Gen, 12 Max Cone Dist, 3.5 Face REF#103
FELLOWS #36-6, 40 Dia, 6 Face, 6 Riser REF#101
GLEASON #16 Hypoid Gear Gen, 9 Max Cone Dist, 2.75 Face REF#103
FELLOWS #36-6 Spur/Helical, 36 Dia, 6 Face, w/Vari Helix Head REF#101
GLEASON #114 Coniflex Str Bev Gear Gen, 7 Max Cone Dist, 2.5 Face REF#103
FELLOWS 100 Dia, 8 Face-Width, Change Gears, Extra Guide, Gears REF#101
GLEASON #24A Coniflex, 1.5 DP, 6" Face, 6" Work Spindle Bore REF#103
FELLOWS #10-2, (10 Dia), 2 Face REF#102
MIKRON #120.1 & 132.02, 1.6 Dia, 25 DP, 50s-60s REF#103
FELLOWS #10-4, (10 Dia), 4 Face REF#102
GEAR TESTERS/CHECKERS (incl CNC)

GLEASON 13, Universal Angular Bevel Tester REF#101
GLEASON #17A, 90-Degree Hypoid Bevel Tester REF#101
FELLOWS #12M, 12 Dia, Involute REF#101
FELLOWS 600RL, 24 Dia, Roll Checker REF#101
Please Check Our Website to View the Gear Testers and Recorders in Our
Inventory REF#103
MISCELLANEOUS
GEAR GENERATORS, SPIRAL BEVEL (HYPOID)
BARBER COLMAN #10 VGS, 10 Dia, 4 Face, 4 DP, New 81 REF#103
WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80 Centers,
FELLOWS #3-3 & #3-1, 3 Max Dia, 1 Face, Pinion Supp, High Precision REF#103
GLEASON #16, 16 Dia Hypoid Spiral Bevel Gear Generator REF#101
FELLOWS #4A Versa, 10 Dia, 3 Face, 4 DP, New 70s REF#103
GLEASON #26, 36 Dia, Hypoid Spiral Bevel Gear Generator REF#101
FELLOWS #4A & 4AGS, 6 Dia, 2 Face, 4DP, 68, Ref.# Several REF#103
FELLOWS #4AGS, 6 Dia, 2 Face, 4DP, Tilt Head Machine REF#103
GEAR SOLUTIONS
SYKES #5B, 60 Dia, 30 Guide 8 Face, New 60s REF#103
REF#103
FELLOWS #FS-630-200, 6-Axis, 24 Dia, 8 Face, 3 DP, 95 REF#103
46
GEAR GENERATORS, HERRINGBONE

SYKES #1A, 12 Dia, 30 Guide and Spur Guide REF#103
MARCH 2007
12 Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965 REF#100
MARKETPLACE
Contact Gear Solutions at 800-366-2185

to feature your business in the Marketplace!
MANUFACTURING EXCELLENCE
THROUGH QUALITY, INTEGRATION, MATERIALS, MAINTENANCE, EDUCATION AND SPEED.
GEAR RACK
SPECIALISTS
STOCK, STANDARDS & SPECIAL GEAR RACK
64 DP TO 12 DP, CIRCULAR & MODULE PITCHES
3
UP TO 31 4 FACE WIDTH AND 157
CONTINUOUS CUT (LONGER BY RESETTING)
QUALITY TO AGMA CLASS II
STANDARD STEEL SPECIALTY CO.

P.O. BOX 20 Beaver Falls, PA 15010
800-356-9232 FAX: 866-338-4279

724-846-7600 Fax: 724-846-9814
email: timo@stdsteel.com www.stdsteel.com
STOCK GEAR RACK AVAILABLE BEST PRICE & DELIVERY
HOB SHARPENING
(763) 425-5247
SPIRAL BEVEL GEARS

Due to customer demands, we have expanded our
STRAIGHT BEVEL ability and added SPIRAL BEVELS
to our capabilities. Our capacities are constantly
expanding, so please forward your specific requirements
for a prompt, competitive quotation.
THIN FILM COATINGS

HSS & Carbide up to 5 Dia.
Straight Gash,
Sharpened & Inspected
Per AGMA STANDARDS
Quick Turnaround
SPIRAL BEVEL
.25 to 33 Diameter
32 DP to 2 DP
.5 Module to 12 Module
STRAIGHT BEVEL
.25 to 36 Diameter
32 DP to 1.5 DP
.5 Module to 16 Module
Manufacturing ALL TYPES of custom gears:

Spiral Bevels, Straight Bevels, Spurs, Helicals,
Worm and Worm Gears, Herringbones, Racks,
Splines, Internal Gears, Sprockets, Ratchets
Tooth Cutting, Grinding & Shaving services available.
Please fax your inquiries

to Dennis Garthus at
708-652-1100
Quality Custom
Gearing Since 1951
KORO SHARPENING SERVICE

9530 85th AVENUE NORTH
MAPLE GROVE, MN 55369
info@koroind.com
CIRCLE GEAR and MACHINE

1501 South 55th Ct. Cicero, IL 60804 Ph: 708-652-1000 Fax: 708-652-1100 circlegear.com
48
GEAR SOLUTIONS
MARCH 2007
ABUNDANT MANUFACTURING, INC.
GEAR GRINDING SERVICES
820 COCHRAN STREET STATESVILLE, NC 28677

PHONE: (704) 871-9911
FAX:
(704) 871-9961
EMAIL: KEVIN@ABUNDANTMFG.COM
WEBSITE: WWW.ABUNDANTMFG.COM
Gear cutting from raw

material to finished parts
Ground tooth gears and
pinions to 1 D.P. and up
to AGMA quality class 13
From 1 Diameter, 64 D.P.

to maximum sizes listed
GEAR GRINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 DIAMETER

GEAR HOBBING . . . . . . . . . . . . . . . . . . . 84 DIAMETER 36 FACE
GEAR SHAPING . . . . . . . . . . . . . . . . . .120 DIAMETER 8 FACE
GEAR SHAVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 DIAMETER
ABUNDANT GEARED TO SERVICE YOUR NEEDS!
Max. Face
Max. Size
Spur Gears
24
92 P.D.
1 D.P.
Helical Gears
24
72 P.D.
1 D.P.
Spur & Helical Gears,

Crown Hobbed
22
72 P.D.
1 D.P.
Internal Gears & Splines
100 P.D.
1-1/4 D.P.
Ground Gears, Crowned or Straight

Herringbone Gears, Center Grove
Max. Pitch
20.5
72 P.D.
1 D.P.
14
36 P.D.
2 D.P.
2182 E. Aurora Rd., Twinsburg, OH 44087

Phone: (330) 425-4419 Fax: (330) 425-8600
www.mwgear.com E-mail: sales@mwgear.com
PRECISION GROUND
SPUR / HELICAL GEARS WORMS
WORM GEARS GROUND RACKS
PROTOTYPE OR PRODUCTION
MAKE COMPLETE OR
OPERATIONAL INCLUDING:
GEAR BOXES & ASSEMBLY GEAR
PUMPS AEROSPACE MILITARY
COMMERCIAL HOBBING SHAPING
TURNING JIG GRINDING
M&M GEAR INSPECTION
NITAL ETCH MAGNAFLUX
24649 Mound Road Warren, MI 48091

Phone (586) 754-4600 Fax (586) 754-4603
Email: spgear@ameritech.net
INNOVATIVE
RACK
& GEAR
C O M P A N Y
Custom Manufactured
GEARS & GEAR RACKS
??
Various Rack Shapes, Sizes & Materials Unique Tooth

Configurations Heat Treating Complete Machining
Accuracy Tolerances up to AGMA Q12 Spur, Helical,
Relieved, Tapered, Crowned
Crowned Breakdown
BreakdownService
ServiceAvailable
Available
Reverse
Engineering
Capability
Reverse
Engineering
Capability
(248)
(248) 601-8145
601-8145 FAX
FAX (248)
(248) 601-0505
601-0505
797 EAGLE DRIVE BENSENVILLE, IL 60106

630-766-2652 FAX 630-766-3245 WWW.GEARACKS.COM
Email:
Email: dsmith@colemfgsystems.com
dsmith@colemfgsystems.com www.colemfgsystems.com
www.colemfgsystems.com
MARCH 2007
GEAR SOLUTIONS
49
< CONTINUED FROM PG. 35
industry. Various sizes of internal gear forms

and involute splines are used extensively in
the automotive industry.
FIGURE 4
Considerations
Broaching is not suitable for every situation.
Like any machining operation, it has its limitations. Several of these must be taken into
account before determining whether broaching
is right for a certain application.
The first consideration is the workpiece surface. If the surface to be broached isnt parallel
to the direction the workpiece or tool travels,
broaching may be inappropriate. Also, if the
broachs passage over or through the workpiece is obstructed, another method should
be sought.
Secondly, complex, contoured surfaces having curves in two or more planes cant be
formed in a single broaching pass, except in
the case of broaching helical gear teeth. In helical broaching, the broach and gear teeth are
uniformly rotated in relationship to each other.
The gear and broach must rotate at the desired
helix angle as the broach is pulled through the
piece to obtain the proper relationship.
Finally, the broached part must have sufficient strength to resist the forces exerted
by the broach. Likewise, these forces also
demand that machines and fixtures be rigid.
Parts with thin walls or cross sections may
prove too fragile for broaching. This is true
for narrow slots as well, because the broach
tools would have to have extremely thin cross
sections.
Broaching wont solve every metal-cutting
problem. But if the workpiece design and production volume lend themselves to it, broaching could prove to be the most efficient, least
costly way to manufacture top-quality parts.
ABOUT THE AUTHOR:

Chris Van De Motter is president of The
Ohio Broach & Machine Company, which
is located in Willoughby, Ohio. To learn
more call (440) 946-1040, send e-mail
to sales@ohiobroach.com, or go online to
[www.ohiobroach.com].
50
GEAR SOLUTIONS
MARCH 2007
advertiserINDEX
COMPANY NAME
PAGE NO.
Abundant Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Advent Tool & Mfg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
AGMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Allen Adams Shaper Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Allied Sinterings Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Atlanta Drive Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Bourn & Koch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Broaching Machine Specialties . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Buffalo Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
BuyPass Dealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Canada Broach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Circle Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Cole Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Colonial Tool Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
CST - Cincinnati . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Encoder Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,50
Forest City Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27
Gear Consulting Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Gear Manufacturing, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Gear Motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Gear Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Gleason Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IFC
Hanik Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
High Performance Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Hydra-Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Index Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Innovative Rack & Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
James Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
KAPP Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KISSsoft USA LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Klingelnberg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Koro Sharpening Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Machinetools.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Midwest Gear Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Mitsubishi Gear Tech Ctr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC
Mohawk Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Moore Gear & Manufacturing Co. Inc. . . . . . . . . . . . . . . . . . . . . . . .14
Nachi America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
New England Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Overton Gear & Tool Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Process Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Quality Transmission Components . . . . . . . . . . . . . . . . . . . . . . . . . .51
R P Machine Enterprises Inc . . . . . . . . . . . . . . . . . . . . . . . . . . .3,11,22
Raycar Gear & Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Repair Parts Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Riverside Spline & Gear Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Saikuni/Dreamtec Consulting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Schwartz Precision Gear Co.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Setco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Standard Steel Specialty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Stor-Loc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Tech Induction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
The BroachMasters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
The Ohio Broach & Machine Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Tianjiu Jingcheng Machine Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Ty Miles Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Tyrolit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,49
Welter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBC
MARCH 2007
GEAR SOLUTIONS
51
Q&A
Our Conversations
With Industry Leaders
billMOORE
Senior vice president of sales
development & channel management
SKF USA
bearings, four seals, Loctite, and some

sealant, a manufacturer can work with
their distributor to develop a kit containing
those particular items, and they can be of
var ying sizes depending on the particular
type of gearbox theyll be making from one
week to the next. That way you can call
your distributor and have exactly what you
need delivered just by ordering the particular kit number in whatever quantities you
require. And what the OEM gains by that is
being able to go to one source and place
a single order, instead of several, and they
dont have to keep as much inventor y on
hand, either. That really plays well into
this flexible, just in time manufacturing
environment that many OEMs are currently
engaged in.
GS: You have an interesting job title.

What does your position entail?
BM: Ive been with SKF for almost 25 years
now, and Ive worked in nearly ever y division we have, from automotive to our OEM
and aftermarket businesses, and Ive been
ever ything from a salesman to a manager
in each of those divisions. My current job
is to manage SKFs industrial aftermarket
business, including the best selection of
go to market channels, if you will. So my
responsibility is to help review the options
for taking a product or ser vice to market,
make a decision about the best method of
deliver y, and then work within that channel
to deliver it to our customer base.
GS: Im assuming these channels
can involve distributors, correct?
BM: Thats right. While we do sell direct
to certain manufacturers, if thats what
works best for ever yone involved, the most
important point is that the customers
needs are being met, and that often
involves the ser vices of one of our qualified distributors. A good example would be
a gearbox manufacturer who contacts us
wanting to purchase bearings and seals.
I would first ask them about who theyre
currently buying from, what their lead times
are, the quantities they would be ordering
at a given time, and what other products
they need for this particular gearbox. There
are many reasons for wanting answers to
these questions, one being that we would
probably need to ship in higher quantities
than theyd want to order all at once
unless theyre truly a high-volume OEM
and another being that certain bundling
opportunities might exist if they choose to
work with a local distributor. Sure, we can
provide them with bearings and seals, but
what about Loctite to make sure their bolts
dont back out, and shims and sealants?
Thats where a relationship with one of
our distributor partners can really come in
handy. If an average gearbox requires four
GS: Thats a great point. Id never

really thought of a distributor
supplying that service.
BM: Distributors can provide a tremendous
ser vice to OEMs. Another example would
be a gearbox manufacturer who wants to
include an oil level coolant heat exchanger
in their design. In that case you would have
the option of either making the subassembly yourself or outsourcing the work,
and I know of a couple of instances where
distributors have gone so far as to put that
together for their customer themselves.
So thats when the relationship actually
becomes an additional outsourcing mechanism, which really helps the customer
streamline their manufacturing process.
So the message were tr ying to send to
the OEM market is that we want to help
them understand the total cost of product
procurement and ownership, because in
todays business climate where customers
demand fast ser vice, speed of deliver y is
almost as important as price. And when
you take that into consideration, along with
all of the additional ser vices they can provide, the industrial distributor can really be
something of a hidden gold mine.
FOR MORE INFORMATION:

Visit the companys Web site at [www.skfusa.com].
52
GEAR SOLUTIONS
MARCH 2007
WE WANT TO HELP OEMS

UNDERSTAND THE TOTAL
COST OF PROCUREMENT,
BECAUSE IN TODAYS BUSINESS CLIMATE SPEED OF
DELIVERY IS ALMOST AS
IMPORTANT AS PRICE.
B BI N G
O
H
Each of Mitsubishi's E series machines

has been designed for their specific
SH
applications. Using the tools of Finite
ING
P
A
Element Analysis and three dimensional CAD, Mitsubishi has optimized

their machine designs to efficiently
GRIN
DIN
and economically produce gears. Each

unique design is capable of handling
G
all of the varied loads, stresses, heat
and process by products generated by
the cutting or grinding conditions.
3 UNIQUE MACHINES!
3 PURPOSE BUILT DESIGNS!
Mitsubishi Heavy Industries America, Inc.
Machine Tool Division
G e a r Te c h n o l o g y C e n t e r
46992 Liberty Drive
|
Wixom, Michigan 48393
P: 248.669.6136
|
F: 248.669.0614
m i t s u b i s h i g e a r c e n t e r. c o m
For Return Information, Fax To:

205-380-1580

Determining Gear Efficiency

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ITS DEFINITELY BETTER TO TAKE A

standpoint. Each of these processes have

ABOUT THE AUTHOR:

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ISO MADE THE FIRST ATTEMPT

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being in someone elses hands, so he

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FOR MORE INFORMATION:

Determining the Momentary Dynamic (Mechanical)

with: Fm - the motive force (the driving force);

FIGURE 1: THE FORCES OF THE GEAR

The consumed power (in this case the driving power):

The Geometrical Elements of the Gear

The lost power will be written:

One determines the next geometrical elements of the external gear,

The momentary efficiency of couple will be calculated directly with