Pure Powder—PURE POWER!

Nixon’s History of
HARD TURNING
SPECIAL SERIES:
Layout Guides
Company Profile:
ALLIED SINTERINGS, INC.

ALSO:
SITE SAFETY
TOOTH TIPS
LASER’S EDGE
Q&A: Jerry Hendrickson /
WILLMAN INDUSTRIES RAW MATERIALS
BUILDING BLOCKS OF THE INDUSTRY

A MEDIA SOLUTIONS PUBLICATION JANUARY 2006

 CUSTOM BEVEL GEAR MANUFACTURING
PER YOUR SPECIFICATIONS AND/OR SAMPLE
PROVIDING INVERSE ENGINEERING TO MAKE A CLONE OF YOUR SAMPLE

• SPIRAL BEVEL GEARS: 66" PD • IN-HOUSE STEEL MATERIAL WAREHOUSE

• STRAIGHT BEVEL GEARS: 80" PD • FULL HEAT TREATING SERVICES
• SPURS-HELICALS-SPLINE SHAFTS • EDM WIRE BURNING
• G E A R B O X R E PA I R / R E B U I L D S

BREAKDOWN
BREAKDOWN SERVICES
SERVICES
4809 U.S. HIGHWAY 45 • SHARON, TN 38255
TOLL FREE: (800)-238-0651 • PHONE: (731)-456-2636 • FAX: (731)-456-3073
EMAIL: [email protected] • www.brgear.com
Family owned and operated since 1974

2 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

 JANUARY 2006
A MEDIA SOLUTIONS PUBLICATION

W W W. G E A R S O L U T I O N S O N L I N E . C O M

FEATURES

26 companyPROFILE ALLIED SINTERINGS, INC.

BY RUSS WILLCUTT
As an established expert in miniature powder-metal gears, this company has spent
46 years focusing on the prospect of “infinite smallness.”

28 CASE STUDY: HARD FINISHING AT NIXON GEAR

BY SAM HAINES AND RON WRIGHT
p. 26 Well-known for its hard finishing capabilities, Nixon Gear—a member company of
Gear Motions—outlines its evolution toward earning a reputation for excellence.

32 PURE POWDER, PURE POWER!

BY LARS TAFLIN
ASP steels—now made with the newly developed DVALIN process—from Erasteel
help manufacturers produce efficient, long-lasting, precision machine tools.

36 SPECIAL SERIES: LAYOUT GUIDES

PART I: STRAIGHT BEVEL GEARS
BY RUSSELL BEACH
This series is intended to provide design engineers working on right angle geared
applications with the knowledge necessary to further their work in-house with mini-
p. 28 mal input from inside or outside gear specialists.

DEPARTMENTS
8 industryNEWS
New products, trends and developments in the gear-manufacturing industry.

20 siteSAFETY TERRY MCDONALD

The beginning of a new year is the ideal time to review your safety program, includ-
ing checking and replenishing your first aid equipment and supplies.

p. 32 22 toothTIPS NICK SUDZUM

This month’s column is the fifth installment of six on bevel gearing, and the
conclusion will cover new finished products.

24 laser’sEDGE JOEL DEKOCK, PH.D.

When designing for laser welding, the materials to be used must be taken into con-
sideration—especially how to overcome the challenges they present.

52 Q&A with JERRY HENDRICKSON, Sales Manager, Willman Industries

INDUSTRY RESOURCES
45 MACHINES 48 MARKETPLACE 51 ADVERTISER INDEX
p. 36
gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 5
from the managingEDITOR
VOLUME 4 NO. 34
PUBLISHED BY

It
’s a word that keeps surfacing during the interviews I’ve conducted for the
company profiles, Q&As, and other features I’ve written over the past MEDIA SOLUTIONS, INC.
year… diversification. It seems that the companies who embrace this con- P. O. BOX 1210 • PELHAM, AL 35124
cept aren’t quite as shaken as those who specialize in particular products, 1-800-366-2185
or markets, when the economy quakes. And there are many other factors
that can deal you a blow, as well. If you’re strictly involved in automotive or PUBLISHER
aerospace applications, for instance, then you’re basically a hostage to DAVID C. COOPER
whatever happens in that industry—whether it involves union demands or foreign com-
petition. And if you produce one type of gear, or provide a single well-known service, VICE PRESIDENT
then you are similarly exposed. It’s not like this is breaking news to any of you, but CHAD MORRISON
there may be some comfort in knowing that others are thinking the same thoughts,
and that the ones who’ve acted on it have benefited from their foresight. OEMs are NATIONAL SALES MANAGER
acting on it as well, designing multi-purpose machines that allow small job shops to BRAD WHISENANT
expand their capabilities, and retrofit companies are helping their customers “gear up”
to manufacture new products or perform additional processes, sometimes at their own
OPERATIONS/CIRCULATION
customer’s request. Expanding into markets peripheral to your own can sometimes
TERESA HALL
make good sense, and it could help you keep a firm footing when one sector is going
through a slump—or vanishes altogether!
ADMINISTRATIVE ASSISTANTS
MICHELE HALL
Another good way to remain agile and forward-thinking is to stay on top of develop-
ments in the area of raw materials. Lars Taflin, ASP product manager at Erasteel, has
PRODUCTION
written a fascinating feature on the powder metallurgical high speed steels his company
produces. Studying the example of others can also help us plot our own course, and
there’s lots to learn in the case study—penned by Sam Haines, who is president of ART DIRECTOR
Nixon Gear, and Ron Wright, its development engineering manager—examining the com- ANDY SPAIN
pany’s decision years ago to focus on hard grinding and then to incorporate robotics
into its production activities. In addition, we’re delighted to present another opportuni- EDITORIAL
ty to learn in the first in a special three-part series of layout guides written by Russell
Beach, a mechanical engineer and vice president of sales for the Nissei Corporation of MANAGING EDITOR
America. The first installment addresses straight bevel gears, the second will cover spi- RUSS WILLCUTT
ral and Zerol® bevels, and the third will discuss hypoid gearing. Russell says that he’s
written this series in order “to provide design engineers working on right angle geared CONTRIBUTING WRITERS
applications with the knowledge necessary to further their work in-house with minimal RUSSELL BEACH
input from inside or outside gear specialists,” so this is an excellent opportunity to build JOEL DEKOCK, PH.D.
on your design skills and increase your professional competency. SAM HAINES
Columns this month include “Laser’s Edge” by Joel DeKock, Ph.D., of Preco Laser TERRY MCDONALD
Systems; “Tooth Tips,” written by Nick Sudzum of B&R Machine and Gear Corporation; NICK SUDZUM
and “Site Safety,” which is presented each month by Terry McDonald, of Repair Parts, LARS TAFLIN
Inc. Our profile is Allied Sinterings, Inc., featuring the company’s president, Mark RON WRIGHT
Foster, and Jerry Hendrickson, vice president of sales at Willman Industries, Inc., is
our Q&A subject—and he has some interesting comments on his own company’s
approach to diversification, I might add. BPA WORLDWIDE MEMBER
So we hope you enjoy this issue of the magazine, and that you’ll keep the press APPLIED FOR AUGUST 2005
releases and story ideas coming in. All best:
THE VIEWS EXPRESSED BY THOSE NOT ON THE
STAFF OF GEAR SOLUTIONS MAGAZINE, OR WHO
ARE NOT SPECIFICALLY EMPLOYED BY MEDIA
SOLUTIONS, INC., ARE PURELY THEIR OWN. ALL
“INDUSTRY NEWS” MATERIAL HAS EITHER BEEN
Russ Willcutt SUBMITTED BY THE SUBJECT COMPANY OR
Managing Editor PULLED DIRECTLY FROM THEIR CORPORATE
Gear Solutions magazine WEB SITE, WHICH IS ASSUMED TO BE CLEARED
[email protected] FOR RELEASE. COMMENTS AND SUBMISSIONS
(800) 366-2185 ARE WELCOME, AND CAN BE SUBMITTED TO
[email protected].

© 2006 MEDIA SOLUTIONS, INC.

6 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com
industryNEWS New Products, Trends and Developments
in the Gear-Manufacturing Industry

Sunnen Introduces New SV-10 Vertical

Honing Machine
Sunnen’s new SV-10 vertical honing machine combines the latest
technology with the consistency and dependability of Sunnen’s leg-
endary CV-616. With two motors—one for the spindle and one for
the stroker—the SV-10 has the capability to run traditional tools,
as well as Sunnen’s new DH-series diamond hone head. Sunnen’s
expertise, with multiple-diamond honing on the top-of-the-line CK-
21, is now available on the competitively-priced SV-10. The DH-
series diamond hone, with 16 points of cutting action, is the
choice for truly round bores. The mechanical stroke guarantees
precision surface finish with consistent crosshatch angle in each
cylinder no matter what tool is used.
Another new feature is the patented full bore profile display
which projects a real time graphical display of the bore cross sec-
tion. This feature actually displays the geometry of the bore—there
is no need for visualization and guesswork. A zoom feature maxi-
mizes the bore view. Also, during the cycle, the SV-10 lets the
operator dwell the honing tool anywhere throughout the bore. The
dwell pointer can be moved to the position where the bore is visu-
ally smaller and the tool will dwell there as long as necessary.
Variable spindle RPM and stroke speed allows an infinitely variable
crosshatch angle for any bore diameter and cylinder length combi-
nation for today’s low-tension piston rings. The new SV-10 Vertical Honing Machine from Sunnen
The SV-10 remains a competitively priced and cost-efficient verti-
cal honing machine and is a versatile addition to any shop. The production, and Klingelnberg—formerly Oerlikon—has covered the
system is ideal for precision honing of .750 to 8 in.(19 -203 mm) market for small- and middle-series production. The new concentra-
bores in applications such as small engine blocks, air compressor tion underlines the core competence of Liebherr for cylindrical gears
cylinders, valve bodies, and aircraft cylinders. and merges all resources of this strategic alliance for even more-
To learn more call (800) 772-2878 or go to [www.sunnen.com]. superior products and, therefore, a larger presence in the market.
The Sigma Pool is not only securing its own position, but it also
Sigma Pool Concentrating offers to all customers an enhanced partnership for development,
Cylindrical Gear Grinding Activities production, and solutions for their ever-increasing quality demands.
In order to secure market leadership and extend the quality of the Effective immediately research and development, production,
OPAL/SIGMA OPAL series, the Sigma Pool partners have decided to and sales for the OPAL/SIGMAOPAL series will be the responsibility
merge all activities in the field of cylindrical gear grinding under the of Liebherr-Verzahntechnik GmbH. This means its customers will
auspices of Liebherr-Verzahntechnik GmbH in Kempten, Germany. have only one contact/partner for cylindrical gear grinding over the
For many years Liebherr cylindrical gear grinding machines have whole production range. Existing contracts will naturally be fulfilled
been very successful in the industry, especially for large-series by the respective partners.

TO SUBMIT
Companies wishing to submit materials for inclusion in Industry News should contact Managing Editor Russ Willcutt at [email protected].
Articles accompanied by color images will be given first consideration.

8 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

 Service in the future will be provided via a “Know-How” program • A roll stand (to check gear contact, simulate housing paral-
in order to secure the most effective customer support possible. lelism, and system integrity)
This transfer will be competed at the end of 2006, and until that • EPA-approved painting and cleaning facilities with water and
time the Klingelnberg Service Organization will continue to offer waste recovery system
unrestricted availability to its customers.
To learn more contact Andreas Montag at amontag@ The Houston facility features three on-site test stands. Each
klingelnberg.com. Also visit [www.sigma-pool.com]. stand offers 35,000 horsepower, 25,000 RPM input speeds,
and API and load testing capabilities. In addition, the facility—
Philadelphia Gear Opens New Regional like all of the company’s regional ser vice centers—has
Facility in Houston, Announces Internet-based access to Philadelphia Gear’s world-class
Appointment Engineering and Technical Center in Norristown, Pennsylvania,
Philadelphia Gear Corporation, a full-service provider of gearing and and its vast librar y of drawings, engineering standards, and
power transmission solutions, has announced the opening of its manufacturing process standards.
new Gulf Coast Regional Service Center in Houston, Texas. In addition, the company has announced the hiring of Mark
Philadelphia Gear had served the U.S. Gulf Coast for over 20 Cooke to the position of regional sales manager for the Gulf
years from its original Houston location. The new state of the art Coast region. He will be responsible for overseeing a sales team
facility encompasses over 40,000 square feet of office and manu- that ser vices Philadelphia Gear’s Gulf Coast Region, including
facturing space, and is equipped with the following capabilities: Louisiana, Texas, Arkansas and Oklahoma. Cooke is also respon-
sible for leading business development initiatives throughout
• On-site grinding, hobbing, and shaving Latin America.
• Electronic gear checking Cooke brings 30-plus years of sales and managerial experience
• A 35-ton crane capacity to Philadelphia Gear. Prior to his position with PGC, Hansen
• A comprehensive machine shop Transmissions employed Cooke as a general manager, overseeing
• Isolated dirty and clean work areas a business team that doubled sales of both their lead product line
• On-site engineering and technical consultations and “spare and repair” business in two years. He also brings sales

• Gears complete to print up to 16 inches in

diameter offering AGMA class 12 quality
• Gear grinding services up to 27.5 inches in
diameter featuring Hofler Helix 400 and 700
CNC Gear Grinders with onboard gear analyzers
• Quantities of 1 to 100 pcs.
• Analytical Gear Charts to insure quality

4884 STENSTROM ROAD • ROCKFORD, IL 61109

PHONE: 815-874-3948 • FAX: 815-874-3817
w w w . r a y c a r g e a r . c o m

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 9

and marketing experience to PGC, gained while working for General fitting, or benchwork in order to eliminate blend lines. Plastic parts
Electric and other companies. of this process were also on display for review. Also introduced
“Philadelphia Gear is pleased to appoint Mark Cooke as our was a unique weldless mold technology.
regional sales manager for the Gulf Coast Region,” says Carl Rapp, All the demonstrations showed Makino’s ability to reduce cycle
president and CEO, Philadelphia Gear Corporation. “We’re confident times and lead times, and eliminate costs, in the production of com-
his managerial experience—and the long history of past accom- plex molds and dies with superior accuracies and surface finishes.
plishments associated with it—will translate to continued success Makino is a global provider of advanced machining technology
in the Gulf Coast for Philadelphia Gear and our customers.” and application support for the metalcutting and die/mold indus-
Cooke’s educational background includes a bachelor of science tries. Makino manufacturing and service centers are located in the
degree in marketing with a minor in aeronautical engineering from United States, Japan, Germany, Singapore, Italy, France, Korea,
Purdue University’s Krannert School of Industrial Management. He Taiwan, Turkey, China, Mexico, Brazil, and India, and are supported
has also taken various sales and management courses. Cooke by a worldwide distributor network. For more information call (800)
also serves on the American Gear Manufacturers Association 552-3288 or go to [www.makino.com].
(AGMA) Board of Directors, and is chairman of the AGMA
Statistical Committee. Boyd Swearingen will remain general manag-
er of the Gulf Coast region, which is headquartered at the new
Houston facility.
For more information call (800) 766-5120 or visit online at
[www.philagear.com].

Makino Holds Die/Mold Technology Expo

The “Built for Die/Mold” Technology Expo held at the Makino
Die/Mold Technologies Center in Auburn Hills, Michigan, was a
huge success. Over 450 people were in attendance from October 4-
6, 2005. The Expo brought together various leaders of the die/mold
industry under one roof to address the state of the North American
tool/die/mold manufacturing market. Attendees were also able to
observe a number of new, innovative process solutions.
Jeff Mengel, a partner with the accounting firm of Plante &
Moran, specializes in working with clients in the plastics industry
as a member of the firm’s Plastics Industry Team. He provided
Makino Die/Mold Technology Expo
the results of a “state of the industry” survey that the firm
recently conducted. Jim Bouck, a manager with Plante & Moran’s
Process and Quality Management Consulting Practice and the Dynamic Five-Axis Fixture Offset by
Plastics Industry Team, presented information on how mold manu- Mitsui Seiki
facturers can implement the latest in “lean manufacturing” princi- Mitsui Seiki USA announces the availability of an advanced dynamic
pals. He illustrated clearly how lean concepts, selectively applied, five-axis fixture offset function on its Fanuc controlled five-axis
can increase the profitability of mold manufacturers. Rod Jones is CNC machining centers. This feature allows tremendous versatili-
president and founder of the manufacturing-based sales and mar- ty and reduced par t changeover for high precision four- and five-
keting consulting firm Decision Technology, Inc. He presented on axis simultaneous machining, in addition to five-sided and polyhe-
how to keep existing customers satisfied, how to develop new dral machining.
customers in existing markets and how to find new customers in One of Mitsui Seiki’s newest machines, the Vertex 550-5X, 5-
emerging markets. axis vertical machining center, is equipped standard with the new
Various industry experts also highlighted the latest advance- Fanuc 31i control, which has many features to support precision
ments in technology, tooling, CAD/CAM systems, materials, and high speed five-axis applications and is the fastest of its kind. The
metal cutting processes. Experts in die/mold machining technology advanced dynamic five-axis fixture offset function incorporated in
and processes were available to discuss specific process solution the control is exclusive to Mitsui Seiki, and is not available on
applications. Demonstrations were conducted on 17 machines, other machine brands.
each providing a specific metal cutting solution. These demonstra- According to Scott Walker, president of Mitsui Seiki USA, four-
tions included new metalcutting methods, high-performance hard and five-axis simultaneous machining of complex shapes—par tic-
milling, Ram and wire EDM processes, fine hole processes, ularly simultaneously contoured aerospace and medical device
automation, lead-time compression and micromachining tech- par ts—are sometimes difficult to run in production because par t
niques. A unique sunglass mold development process was exhibit- form accuracy and sur face finish are often the direct result of
ed that illustrated milling techniques which required no polishing, how well the par t is fixtured. In many applications, the par t

10 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

datum must be aligned per fectly at the
“programmed center points,” which take
into account the orbiting points of the
rotar y axes, or the par t program must be
reposted to offset the error in setting up
subsequent par ts. The results are usually
the same: either the manufacturer has to
utilize ver y elaborate fixtures, or the oper-
ator must be diligent enough to set the
new par ts back on center. With Mitsui
Seiki’s advanced dynamic five-axis fixture
offset compensation, the operator can
simply apply a work coordinate offset
adjustment and the control will continu-
ously track and update the par t pro-
grammed vector points dynamically in real
time. In some cases a spindle probe can
be utilized to pick up the necessar y par t
datums and apply the five-axis work coor-
dinate offsets automatically.
The standard Fanuc controls have a
“rotary table dynamic fixture offset” func-
tion, which calculates the vector for the
destination of the rotary axis command
and offsets the X-, Y-, and Z-axis destina- Mitsui Seiki’s five-axis fixture offset
tion accordingly. This scheme is suitable
for five-sided machining and only works
when the centerline of the rotary axes
intersect at right angles.
The advanced Mitsui Seiki dynamic five-
axis fixture offset function continuously cal-
culates the offset vector for current posi-
tion and offsets X-, Y-, and Z-axis position
accordingly in real time. As a result, not
only can the machine be used for five-
sided machining, but also four- and five-
axis simultaneous machining.
Dynamic five-axis fixture offset is fea-
tured on Mitsui Seiki’s new Vertex 550-5X
VMC, an exceptionally compact and fast
vertical machining center that delivers high
volumetric accuracy. The machine has a
standard 15,000-rpm spindle with 25,000-
rpm available as an option.
To learn more call (201) 337-1300 or go
online to [www.mitsuiseiki.com].

BIG Kaiser Introduces

Sphinx Quadro Plus Drill
Line Addition
BIG Kaiser Precision Tooling, Inc., intro-
duces the newest addition to its high-per-
formance Sphinx Quadro Plus drill line.
With its specially-designed point geometry,

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 11

Quadro 15 PLUS is ideal for cutting steel, cast iron, and other non- Kaiser’s mission is to suppor t Nor th American manufacturers
ferrous materials. with products that are designed and manufactured to a superior
The sophisticated engineering behind the Quadro 15 PLUS standard.
makes it ultra-rigid, requiring less cutting force and increasing For more information contact BIG Kaiser—which is based in Elk
feeds and speeds. Quadro 15 PLUS can drill up to 50 percent Grove Village, Illinois—at (847) 228-7660. Send e-mail to
faster and can hold close tolerances, achieving a hole quality of [email protected], or visit [www.bigkaiser.com].
H7 or better. Quadro 15 PLUS maximizes productivity by eliminat-
ing the need for subsequent finish operations, delivering a quality Curtiss-Wright Receives F-35 JSF Contracts
surface finish of Ra 0.8 µ (32rms). Balzer’s Futura Nano Top TiAIN Curtiss-Wright Corporation—through its Motion Control segment,
Coating optimizes chip evacuation, increases wear resistance, and Curtiss Wright Controls Inc.—has received contracts from
results in longer tool life. Lockheed Martin Corporation for the Joint Strike Fighter program
These carbide drills are made from ultra fine-grain carbide and with an initial value of $2.2 million for the System Development
are available in diameters from 4mm (.157”) to 20mm (.787”) in and Demonstration (SDD) phase and a potential value of $120 mil-
standard length of six-times diameter with coolant through. Based lion for the total program requirements. Curtiss-Wright will supply
on the highly successful Quadro Plus drill geometry of Sphinx, the the Ordnance Hoist System (OHS) and Ordnance Quick Latch
new 15-degree helix angle makes them suitable for drilling long System (OQLS) for the F-35 Joint Strike Fighter (JSF).
chipping materials such as steel as well as cast iron. “Curtiss-Wright is proud to support the Joint Strike Fighter
Based in Biberist, Switzerland, Sphinx received the original Swiss Program as it is strategic to our national security,” says Martin R.
patent for a twist drill in 1897. Sphinx produces approximately Benante, chairman and CEO. “We have a long history with
1,200 standard drills and as many as 1,200,000 different drills, Lockheed Martin and we look forward to continuing to support
including their custom lines. their programs for many more years to come.”
BIG Kaiser Precision Tooling is a leader in high precision tool- The F-35 JSF will provide the U.S. Air Force, Navy, and Marine
ing systems and solutions. With brands including Kaiser, BIG Corps, and the United Kingdom’s Royal Navy and Royal Air Force,
Daishowa, Speroni, Unilock, Sphinx, and more, the company’s with an affordable and stealthy tactical aircraft for the 21st centu-
line is focused on extreme accuracy and repeatability. BIG ry. The Lockheed Martin F-35 JSF has been designed to satisfy the

12 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

diverse needs of each of these services with a family of afford- within cellular workstations. Lean manufacturing allows Bison to
able, lethal, survivable, and supportable combat aircraft. offer customers a cost-effective product while working in a flexible
The equipment to be provided is a new requirement designated production environment.
as Alternate Mission Equipment (AME) for ordnance loading, carry- This second annual conference gave top manufacturing leaders
ing, and unloading on all three aircraft variants (CTOL, STOVL, and an opportunity togain hands-on experience with their peers in an
CV). SDD hardware deliveries are anticipated to occur from 2006 interactive conference workshop. The plant tours were followed by
through 2010. The design, development, and manufacturing of workshops that examined the most pressing issues and opportuni-
these products will take place in Curtiss-Wright’s facilities located ties in the industry. Bison Gear & Engineering was honored to take
in Gastonia and Shelby, North Carolina. part in this prestigious event.
For more information contact Alexandra M. Deignan at (973) 597- To learn more call David Rosenberg at (800) AT-BISON—or 282-
4734. Go online to [www.curtisswright.com] or [www.cwcontrols.com]. 4766. Also send e-mail to [email protected], or visit the
company’s Web site at [www.bisongear.com].
Industry Week’s SMART/MFG 2005
Conference Visits Bison Jicey Introduces New Laminated,
Industr y Week’s SMART\MFG 2005 three day conference kicked Peelable Shim
off with an on-site tour of Bison Gear and Engineering. Hosted by Jicey Precision Shims, a French specialist in industrial precision
Senior Vice President of Operations George Thomas, over 30 shimming, introduces the Alkomposit Viewtek, a laminated shim
manufacturing colleagues were given an in depth behind the with peelable layers to adjust its thickness. Made of stacked com-
scenes look at Bison’s proven plant strategies and lean manu- posite films, its exclusive marking system significantly simplifies
facturing operations. the use of shims for filling space between parts when precision
Attendees learned how Bison has successfully converted its assembly is required.
manufacturing facility to function as a lean manufacturing plant. Each shim is composed of sheets of different thicknesses on
Utilizing a lean system, Bison is able to carry product component each of the two sides, 0.001 in. on one side and 0.004 in. on the
parts in stock, allowing for rapid response to customer needs. other, for example. A patented marking system indicates the thick-
Regularly scheduled Kaizan events allow for maximum efficiency ness of the sheets on the middle section of the shim. Due to the

SWISS PRECISION
FROM:

ph: 011-41-32-344-0400
fax: 011-41-32-344-0404
www.schnyder.com
[email protected]

www.hanikcorp.com
HANIK CORPORATION
271 E. BEINORIS DRIVE // WOOD DALE, IL 60191
PHONE 630-595-7333 // FAX 630-595-7343

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 13

 Paulo-Murfreesboro
Upgrades to ISO/TS
16949:2002
The Murfreesboro, Tennessee, facility of
Paulo Products Company has successfully
passed the upgrade audit and has been
awarded accreditation to ISO/TS 16949:2002.
Created by the International Automotive
Task Force (IATF), ISO/TS 16949:2002
represents the technical standard require-
ments of the major automotive manufac-
turers around the world. What sets ISO/TS
16949:2002 apart from the previous ISO
and QS standards is the requirement to
continually measure, monitor, and improve,
with an emphasis on preventing defects
and reducing waste throughout the supply
chain. In addition to this recent quality sys-
tem upgrade, Paulo-Mur freesboro is
approved to the Ford HTX standard and
has received the coveted Ford “Preferred
Supplier Award.”
Jerry Jenkins, division sales manager for
Paulo-Murfreesboro, says that “The
process of becoming accredited to ISO/TS
16949:2002 requires the involvement and
dedication of everyone in the facility. This
achievement is proof of Paulo’s commit-
ment to practices that enhance not only its
own business developments but also those
of its customers.”
Paulo-Murfreesboro is the second Paulo
Jicey’s new laminated, peelable shim facility to become accredited to ISO/TS
16949:2002. Paulo-Nashville received
accreditation to ISO/TS 16949:2002 in
transparency of the composite material, the operator can instantly see the thickness of April of this year. Other Paulo facilities are
the sheet being peeled. Adjustments can therefore be more exact by peeling off the currently working toward receiving the
thickest sheets first and ending with the thinner ones. Sheet thickness is also identified ISO/TS 16949:2002 upgrade.
by a corresponding color, so one can quickly and easily identify the measurement to Paulo provides a wide variety of innova-
obtain the desired size. tive engineered solutions in heat treating,
The shim’s composite material, a type of polyester called polyethylene terephtalate, has brazing, and metal finishing. Paulo-
many advantages compared to those of metal laminated shims. It costs less, is 50 per- Murfreesboro specializes in production
cent lighter than aluminum, and has an excellent resistance to chemicals and tempera- heat treating, zinc plating, and zinc phos-
ture, ranging from -94° to 428° F. This flexible material is safe and easy to peel by hand. phating. Paulo also offers a broad range of
The sheets can be used for adjustment or sealing, and each one can be reused or used metallurgical services and engineering
as a single shim, greatly reducing assembly times. resources.
Jicey has been a world leader in precision shims since 1946. It produces and distrib- For more information contact Jenkins at
utes a complete range of adjustment shims (peelable shims, solid shims ground or not, (615) 216-3008 or [email protected]. The
separable shims, extra-thin single shims) in all dimensions and materials for aeronautics, company’s Web site is [www.paulo.com].
space, railway, automobile, mechanical engineering, and public works industries. It pro-
duces more than 3 million made to order adjustment shims per year for more than 5,000 Baldor Launches High-
customers throughout the world. Performance PCI-Bus
To learn more contact Jerome Caillas, chief marketing officer, at +33 (0) 1-39-07-10-40, Motion Controller
or send e-mail to [email protected]. The company’s Web site is [www.jicey.com]. Baldor announces its high-per formance

14 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

PCI-bus motion controller featuring ver y fast communications and
response capabilities. Known as NextMove PCI-2, it offers exten-
sive digital and analog I/O and provides a highly flexible all-in-
one control solution for PC-hosted automation applications. The
new controller accommodates position feedback data at rates as
high as 10MHz, and features a ser vo loop update time of just
100 microseconds—twice as fast as its predecessor. It is espe-
cially suitable for multi-axis motion control applications with high
data transfer or processing overheads, such as vision systems
and tasks involving thousands of co-ordinated moves.
NextMove PCI-2 is a second-generation product, based on a
redesigned version of Baldor’s popular single-board PCI-1 con-
troller. Incorporating the latest high speed digital technology—
including a 120MHz 32-bit floating point DSP core—it uses an
FPGA (field programmable gate array) for all drive control and
I/O functions. This helps minimize manufacturing costs and
facilitates product customisation. The new controller is pin
compatible with the NextMove PCI-1, enabling OEMs to upgrade
the per formance of existing machines without changing connec-
tors or cabling.
Available in one, two, three, four, and eight-axis versions,
NextMove PCI-2 controllers are packaged as single, short (seven
inch) PCI cards. Each model can handle closed loop control of
servo or vector drives and open loop control of stepper drives; the
eight-axis version provides four closed loop and four open loop
control channels. An optional four-axis PCI expansion card is avail-
able, and the controller supports up to two cards, subject to a
maximum of 12 control channels of either type.
For controlling ser vo or vector drives, NextMove PCI-2 gener-
ates industr y-standard ±10V analog output signals—with up to
16-bit resolution—and accepts position feedback from an incre-
mental encoder at rates up to 10MHz (or 7.5MHz via an expan-
sion card). The ser vo loop employs a special high speed PID
(propor tional integral derivative) term that includes velocity and
acceleration feedfor ward parameters for precision tuning,
backed by a 100 microsecond update rate for up to four axes.
Open loop axes are controlled via differential step and direction
outputs capable of handling frequencies up to 3MHz; these can
either be used with standard stepper type drives, or with open
loop ser vo drives configured for step and direction inputs.
NextMove PCI-2 controllers are supplied complete with the lat-
est version of Baldor’s Mint multitasking machine control program-
ming language, together with libraries for embedded C programs
and ActiveX control. The controller can either run autonomously
from its own locally-stored Mint or embedded C program, or semi-
autonomously under PC control. The application’s high level con-
trol software and user interfaces can be written in any ActiveX
compliant language, such as Visual Basic or C++, and communi-
cate with the controller’s Mint command library or locally-stored
program via an application program interface (API).
Mint is especially easy to use. It provides a structured, inher-
ently self-documenting approach to program development, and
incorporates a large number of motion control, I/O handling, com-
munications, networking, and operator inter face functions. The

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 15

language is standardized across all of Baldor’s controllers and
programmable drives to help users maximize productivity. Using
Baldor’s Windows-based Mint Workbench application development
tool, engineers can quickly create very lean and efficient motion
control programs.
NextMove PCI-2 controllers feature extensive on-board memory.
There is 2Mb of zero-wait-state SRAM for program and data stor-
age, 32kb of non-volatile RAM, and 16kb of memory-mapped dual-
port RAM—with interrupt capabilities—for high-speed communica-
tion with a host PC via the 33MHz PCI bus. Reserved locations
within the DPRAM are used for diagnostic information such as axis
position and error codes, and are instantly accessible for fast real-
time control purposes.
Ever y NextMove PCI-2 controller offers a high complement of
I/O inter faces to satisfy vir tually all machine control require-
ments and obviate the need for a separate I/O controller such as
a PLC. There are four analog and 20 digital inputs—four of which
offer one microsecond data capture for high-speed position feed-
back purposes—together with a dedicated RS422 master
encoder channel for synchronisation and follower type applica- Loctite’s new benchtop peristaltic dispenser
tions, which can handle up to 10MHz. The controller’s output
capabilities are equally comprehensive; in addition to analog
drive demand signals, it provides 12 digital outputs. A drive air/moisture sensitive products. The rotor can be operated in for-
enable relay output is also provided: This is automatically de- ward or reverse. The instant reverse feature shuts off liquid flow
energised under error conditions, and can be used for imple- and prevents dripping post-dispense. The dispenser can be used
menting fail-safe operation. as a manual or semi-automatic workstation in continuous or
NextMove PCI-2 controllers also feature a 500 kBaud isolated timed-dispense mode. It can dispense drops as small as 0.001
CANbus port. This can be configured for CANopen DS301, with ml, or a continuous bead at a maximum rate of 6 ml/minute. A
support for DS4012 I/O devices, or for Baldor’s proprietary CAN simple and convenient load mechanism also makes tubing
protocol. Using CANopen, the controller can assume the role of replacement quick and easy.
master when communicating with other nodes running Mint soft- For more information call (800) LOCTITE, or send e-mail to
ware, for applications involving distributed machine intelligence. [email protected]. Visit the company’s Web site at
Alternatively, the port can be used to further expand the con- [www.equipment.loctite.com].
troller’s I/O capabilities, by communicating with Baldor CAN-com-
patible digital I/O expansion units. Up to 63 nodes can be News from
installed on the network. Inductoheat
Full details of Baldor’s new PCI-2 controller are contained in the The Inductoheat STA-
company’s NextMove Multi-axis Motion Controllers catalogue, refer- TITRON™ transistorized
ence BR1202-C, which is available free of charge in electronic or induction power supply
printed form. To learn more go to [www.baldor.com]. is configured for galvan-
nealing. Feed rate
New Benchtop Peristaltic Dispenser requirements are accom-
from Loctite modated with proper
The Henkel Corporation has introduced the Loctite® Benchtop power supply size and
Peristaltic Dispenser, a reliable volumetric dispense system for sin- zone lengths. This appli-
gle component, low viscosity fluids. Designed for highly precise dis- cation heated 60” wide
pensing applications that require both dot to dot or continuous 0.0280” thick to the
bead repeatability, this equipment transfers adhesives directly from needed 1050 degrees
the bottle to the hand-held dispense valve. Fahrenheit using a 3
The Loctite Benchtop Peristaltic Dispenser is electromechani- megawatt solid state
cally operated and uses pressure from a mechanical rotor rather STATITRON.
than a pneumatic air source to move adhesives or solvents with Several major North
viscosities up to 5000 cPs. This air-free dispensing method American Steel manufac- Inductoheat’s Gerald Wills
essentially eliminates the problem of premature curing with turers have contracted

16 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

Inductoheat to supply systems of this type in recent years. base. The adjustment features a full zero- to 90-degree position
Customers benefit with dramatically reduced energy expense and requiring no tools for changing.
less floor space using STATITRON. The equipment is over 85-per- For more information call (815) 363-8268, send e-mail to info@
cent efficient, in contrast to 30-50 percent efficiency associated kwikmark.com, or visit the company’s Web site at [www.kwikmark.com].
with gas technologies to do the same job. Each system is com-
prised of three primary components including STATITRON induction Boeing Projects $770-Billion Market for
power supply, water system, and induction coil. New Airplanes in Asia-Pacific
In other news, Inductoheat has appointed Gerald Wills as dis- The Boeing Company detailed its 2005 Current Market Outlook
trict sales manager for Ohio and for the western sides of (CMO) for the Asia-Pacific region recently, forecasting a market for
Michigan, Kentucky, West Virginia, and Pennsylvania. Wills grad- about 7,200 new airplanes worth $770 billion over the next 20
uated from Youngstown State University with a degree in electri- years. Over the forecast period, Asia-Pacific will remain the largest
cal engineering technology, and he has been with Inductoheat market outside North America for new commercial airplanes. With
since May 2005. the continued high rate of growth for Asia-Pacific air travel and air
Inductoheat, Inc.—an Inductotherm Group company—is a major cargo markets, Asia-Pacific’s fleet will nearly triple to about 8,600
manufacturer of induction heating equipment and offers full service airplanes by the end of the forecast period.
parts, coils, and repairs. Inductoheat is both Q-1 and ISO-9001 Nearly 7,200 new airplanes will be needed for future growth and
certified. For more information call (800) 624-6297 or visit online replacement. Single-aisle airplanes, such as the Boeing 737 will
at [www.inductoheat.com]. be the largest category with a total of new airplane deliveries at
3,690 airplanes. Intermediate twin-aisles such as the Boeing 787
Angular Cylindrical Attachment from and 777 will comprise approximately 2,430 airplane deliveries.
Kwikmark Regional jets will total 540 units delivered and 747-and-larger size
The Kwik Turn cylindrical attachment from Kwikmark, Inc., is avail- airplanes will be 510 units delivered.
able with the sign block adapter which allows angular positioning “Passengers are the foundation of air travel, and in a competi-
of the headstock. This devise is easily removable and adapts to tive market the airlines will continue meeting passenger’s
the standard Kwik Turn cylindrical attachment and its associated demands for more direct nonstop flights to destinations around the

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gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 17

world with longer-range, efficient, and comfortable airplanes,” says The TT20 and TT60 Electronic Gage Amplifiers offer seven
Boeing Commercial Airplanes Director-Product Marketing, Analysis, inch/metric analog scales covering a range of ±0.200” to
and Positioning, Randy Tinseth. “This requirement will be met by ±0.0002”/±5 mm to 5 µm with a resolution of .010” to .00001”.
airplanes in the 200-to-400 seat capacity category, with only a few Maximum digital resolution is .000005”/0.1 µm.
very large ones being needed.” The TT60 Electronic Gage Amplifier features dynamic capture of
Between Taiwan and Asia-Pacific, available seat miles have dou- maximum + minimum values and calculates difference (TIR) and
bled since 1990. Most of this growth has been met by increased average values. It includes output selection for 5, 10, 20, or 40
frequency, which has increased 2.5 times during this period. New tolerance classes and selection of analog output ±2V and ±10V for
markets have developed during this period even faster than fre- connection to a recording instrument or separate display. The TT80
quency growth. Since 1990, the average airplane size has Electronic Amplifier includes nine measuring ranges with a numeri-
decreased by nearly 20 percent. cal interval to 0.01 µm or .000001”.
Boeing projects Asia-Pacific air travel growth will outpace the Brown & Sharpe also offers a broad range of gaging transducers
world average of 4.8 percent during the forecast period. Air travel that fit virtually any inspection instrument. Call the company at
for Asia-Pacific's carriers will expand significantly, led by the (800) 283-3600 or go to [www.brownandsharpe.com].
Chinese domestic market’s projected average growth of almost 9
percent. This incredible growth will nearly triple the Asia-Pacific air- Waterjet Cutting System from WARDJet
plane fleet over the next 20 years. Air travel within Asia-Pacific is WARDJet, Inc., introduces its new M-Series of waterjets, which
forecasted to grow six percent per year. Worldwide, Boeing projects enables you to use your CNC mill, laser, wood router, robotic arm,
that operators will invest $2.1 trillion for approximately 25,700 new oxy-fuel, or plasma cutter as a waterjet and drive the intensifier off
commercial airplanes during the next 20 years. The full forecast is compressed air in your shop. Now you can adapt the machinery
available at [www.boeing.com/commercial/cmo/index.shtml]. you own into a multi-tasking system by bringing waterjet cutting
For more information call Linda Lee, Boeing Commercial into your facility at a low price.
Airplanes, at (206) 766-2905. Send e-mail to linda.a.lee@ Retrofitting a CNC mill or other CNC system and then trying to
boeing.com. Go online to [www.boeing.com]. cut with a waterjet on it would be like throwing buckets of sand
and water all over your most treasured machine. The M-Series
High-Performance Measurement addresses and remedies this. A “tent” specifically designed and
Versatility from Brown & Sharpe built to contain all the abrasive and water inside the tank makes it
Brown & Sharpe TESATRONIC® TT20, TT60, and TT80 Electronic possible to keep all M-Series waterjets compact and self-con-
Gage Amplifiers provide accurate measurement capability with two tained. A self-flushing system removes the water, abrasive, and
probe functionality. These electronic gage amplifiers are fitted with any kerf material from inside the tank for disposal.
two inductive half-bridge probe input jacks so they can be used for The 30” depth of water typically used in a large waterjet tank
single measurements with one probe, and sum or difference meas- to dissipate the excess energy of the waterjet stream is
urements using two probes. Readings
appear on a bright, easy-to-read ana-
log and digital display. Data can be
sent to a PC in digital format.
TESATRONIC amplifiers feature a
six-digit dual analog and digital dis-
play that can be selected in inch and
metric measuring ranges. Inch and
metric conversion is instant. These
amplifiers feature programmable tol-
erance limits and automatic scale
selection, based on the measured
value, plus they have the capability
to measure with or without tolerance
settings. Measurement functions ±A
and ±B are selectable. Green, yel-
low, and red LED signals indicate
classification for quick recognition
on the shop floor. Classification of
external or internal dimensions can
be selected. Units are stackable or
TESATRONIC® TT80 Electronic Gage Amplifier from Brown & Sharpe
freestanding with flip-down suppor ts.

18 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

 replaced with a bed of ball bearings. Tanks come with either a
3.5”, 5”, or 8” deep layer of balls to match your cutting needs.
Different size tanks are also available for different size CNC
machines. “Hooking into” outputs used to operate the mill, or
WARDJet’s new waterjet whatever system you are going to use your M-Series with, acti-
cutting system
vates the waterjet cutting head and abrasive feed system.
Because the M-Series waterjets are stand-alone units, there is
no need to learn any new controller or programming methods.
The same programming used to run your existing machine can
be used to operate the waterjet motion.
WARDJet, Inc., manufactures many standard sizes of waterjets,
from 4’x5’ to 40’x13’. It also supplies the patented WARD 1 and
WARD 2 (Waterjet Abrasive Recycling Dispenser) for waterjet com-
panies around the world.
For more information contact Julie Kaiser at (330) 677-9100.
Send e-mail to [email protected] or go online to [www.wardjet.com].

Bunting Bearings Corp.

Earns ISO Certification
Bunting Bearings Corp., a leader in bearing design and manufactur-
ing, was recently honored with ISO 9001:2000 Quality
Management Certification. ISO 9001 has become the most widely
accepted and sought-after quality management system. The imple-
mentation and registration of the ISO 9001:2000 management
continued on page 41 >>

STOR-LOC MODULAR DRAWER SYSTEM

880 N. Washington Ave. Kankakee, IL 60901
Toll Free: 1.800.786.7562 • Fax: 1.800.315.8769
email: [email protected]
www.storloc.com

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 19

siteSAFETY terryMcDONALD
Member of the ANSI Subcommittee on Gear Safety

The beginning of a new year is the ideal time to review your safety program, including commonsense
procedures such as checking and replenishing your first aid equipment and supplies.

“ANY SAFETY PROGRAM WORTH

W
ell, here it is again, another new When I saw that the focus of this
year. I hope that all of you had a month’s issue is raw materials, I asked
very happy and safe holiday period,
and that you’re ready to tackle the
ITS SALT IS CONSTANTLY myself what safety issues could be raised
that are related to this subject. The first
new year with enthusiasm and plans to
improve your workplace safety. Even if we
CHANGING AND IMPROVING, thing I thought of is weight, involving lifting
and moving heavy bars of stock. Then I
have a safety program in place, we have
to realize that with ever y change in mate-
INCLUDING PERIODIC thought about rough finishes that can
cause cuts and scrapes. Other dangers
rials, machiner y, processes, or person- REVIEWS THAT ARE TAKEN include the fact that stock can have oil or
nel, our safety program will require other preservative compounds on it that
updates. Any safety program wor th its VERY SERIOUSLY.” could cause slipping or, even worse, aller-
salt is a constantly changing and improv- gic reactions. All of these are legitimate
ing program. Often a company creates a safety concerns when dealing with raw
safety program and then feels that the common occurrence in everyone’s shop. materials. Employees need to be aware of
requirement has been satisfied, so it is One of my employees came in to work these hazards and taught how to store and
largely ignored from that point for ward. wearing tennis shoes. While this was just handle the materials we receive and use.
We cannot allow that to happen to us. A a lapse of memory on his part, it can be a But raw materials can mean more than just
par t of any safety program must include very hazardous practice. It was fortunate the stock we keep on hand. It can be oils,
periodic reviews that are taken ver y seri- that I noticed and sent him home to coolants, and a myriad of different chemi-
ously. The program will require these change shoes. Often, our employees don’t cals. This means that our Material Data
updates on a regular basis, with the fre- realize the hazards associated with Safety Sheets must be kept up to date so
quency determined by your own compa- improper footwear—especially with many that if there is a problem that relates to
ny’s changes in the above-mentioned of them being young and having been one of these chemicals we can react swiftly
items. If the program is not reviewed at raised wearing tennis shoes. We, as and with the proper actions.
least twice annually, though, then I just employers, are required to teach them the That said, I hope that all of you have a
don’t see how it can be as current and proper way to dress while at work. I’m not happy—and especially a safe—new year!
effective as it needs to be. suggesting that a dress code be imple-
Another thing that is often ignored is the mented, but common sense tells us that
condition and availability of our first aid proper foot protection—as well as eye and
supplies and safety equipment. I have hearing protection—are paramount to our
seen many instances where the simplest employee’s well being. I find that I can
thing, such as a band-aid or ointment, is often miss an item such as proper
not there when you need it, and the first of footwear when observing my employees
the year is an ideal time to check inventory due to being concerned about what they’re
and restock these items. doing rather than what they’re wearing, so
I recently had a situation here at our I know that I must train myself to be more
own facility that I think may be a fairly observant of these factors.

ABOUT THE AUTHOR:

With more than 30 years of experience in the gear industry, Terry McDonald is partner and manager of Repair Parts, 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 [email protected]. The company’s Web site
is [www.repair-parts-inc.com].

20 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

toothTIPS General manager and COO, B&R Machine and Gear Corp.
nickSUDZUM

This month’s column is the fifth installment of six on bevel gearing. It began with the possible failures
determined through vibration and will conclude with new finished products.

last column covered the basics

My of the reverse/inverse engineer-

ing process, which is only the tip
of the iceberg. Let’s assume
that everything went as planned, and the
customer has given you the approval to
proceed using the drawings that you have
submitted. Now is when the planning
phase of the actual manufacturing process
begins, starting with routing the job proper- FIGURE 1: Good contact patterns will lap in with- FIGURE 2: Improper contact pattern
ly so that the end result is correct, and the out any offsets
parts that you have produced are as close
as possible to a clone of the original sam-
ples supplied for duplication.
If questions arise during the manufactur-
ing process it is wise to refer back to the
sample and compare it to your drawings,
which will usually answer your question.
When the situation arises that your answer
is not definitive, consult the end user.
After all of the general machine work is
FIGURE 3: Requires horizontal offsets FIGURE 4: Improperly cut lame contact, must
per formed on the raw material, the next remanufacture pinion to correct the contact pattern
process would be generating the teeth,
testing the gear with the pinion to devel- The common process used to finish out and horizontal) offset criteria to qualify that
op the proper contact/bearing pattern the gear tooth area on a commercial replace- the contact/bearing pattern is properly posi-
and mounting distance. The next step in ment set of gears is lapping. During the lap- tioned. To sum up the lapping process, you
the process would usually be heat treat- ping process an abrasive compound is are able to make small adjustments to the
ing. In most cases the gear set is then applied in the area of the contact/bearing contact area if the initial manufacturing
set up in either internal or external grind- pattern. If the contact/bearing pattern did process was performed properly.
ing machines so that proof datums may not acquire any distortion during the heat In some applications, especially those
be confirmed as concentric and perpendi- treating process, the lapping compound uti- involving higher AGMA quality levels, a light
cular with the pitch diameter produced lized may be very fine grit. This process lightly lapping process may still apply after tooth
during the cutting process. These areas wears in the contact/bearing area or seats grinding, hard cutting, or skiving. This type of
would be hard green ground to regain the the gear sat in to insure the gear set will run lapping is generally performed using an ultra-
original concentricity, usually still leaving properly in its respective housing. In all fine grade liquid compound. The illustrations
stock for a finish grind operation after types/styles of generated bevel gears engi- shown are some basic conditions that may
the finishing operation is per formed on neers look for a central toe contact/bearing exist in the development of contact patterns
the gear teeth. pattern, having what is called V&H (vertical during the cutting process.

ABOUT THE AUTHOR:

Nick Sudzum is the general manager and COO of B&R Machine and Gear Corp. He can be contacted at (800) 238-0651 or [email protected].

22 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

The Used Equipment Industry will never be the same. No longer will the Used Equipment Dealer dictate pricing
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laser’sEDGE joelDeKOCK, Ph.D.
Applications Manager, Preco Laser Systems, LLC

When designing for laser welding, the materials to be used must be taken into consideration—especially
their specific properties and how to overcome the challenges they present.

In
previous columns on designing for
laser welding the topics of access,
restraint, and joint design were
presented. In this column the final
design consideration of material choice is
discussed. Choosing appropriate materials
is a difficult problem since the best per-
forming materials are often the most diffi-
cult to weld. In gear applications the prop-
erties often desired are wear resistance
and toughness. To achieve this steels clas- FIGURE 1 At left is a sample made of steel containing 18 points carbon, the upper right contains 30
sified as low-alloy or alloy steels are often points and the lower 50. Hot-cracking is seen at right, while the low carbon sample at left is defect free.
employed, because they contain additional
carbon for hardening and nickel to promote
toughness. There are other elements which
promote hardening, but it is the carbon
content that is the key to weldability.
Most laser welding applications utilize
steels with carbon contents of 30 points
(0.3 wt. percent) or less. This is primarily
due to the high thermal efficiency of the
process. With minimal heat input, steels
considered not hardenable by heat treaters
can show hardening response in the fusion
and heat affected zones. Steel with good
FIGURE 2 At lower left is a gear made from 8620, and upper left is 1120, neither carburized in the weld
hardenability and just 20 points of carbon zone. Both welds were carburized at right.
can reach a hardness of 48 Rc, which can
concern a metallurgist because this repre-
sents a fully hard Martensitic structure. The important in the welding of steels with in porosity, and; free machining steels con-
process engineer can minimize hardening in greater than 40 points of carbon. taining high levels of sulfur, phosphorous,
the HAZ by maximizing heat input, but at Nitrogen is another element that is often selenium, cadmium, or lead, due to hot crack-
approximately 40 points carbon additional used in the hardening of steels. Laser welding ing and porosity problems.
energy is required to suppress or affect nitrided steels should be avoided, because As for application examples, the welding
Martensite in the HAZ. In addition to the the welds can exhibit cracking and porosity. If of two different products is presented here
hardening response promoted by increasing the nitrided layer is removed at the weld loca- to provide some perspective of the variety
levels of carbon, weld quality will degrade, tion, this problem is avoided. Other concerns of approaches that can be taken. These
resulting in welds which exhibit poor solidifi- include: sulfur and phosphorous, which examples are the welding of medium car-
cation (hot cracks) or porosity. Maximizing should be below 0.05 percent to prevent hot bon steels, and the welding of carburized
heat input and controlling solidification are cracking; zinc coated steels, which can result gear to a low carbon ring.

ABOUT THE AUTHOR:

Joel De Kock, Ph.D., is applications manager for Preco Laser Systems, LLC. He is a member of the American Welding Society, ASM International, and the
Laser Institute of America.

24 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

 The first example is the welding of two
different medium-carbon steels, one con- Manufacturers of Precision
taining 30 points carbon and another con- Gear Cutting Tools
taining 50 points carbon. This particular
• shaper cutters
application is challenging because of the • shaver cutters
higher carbon material, and thus requires • master gears
heating of the assembly prior to and after • chamferring & deburring tools
welding. Induction heating is used to local- • spline gauges
ize the addition of heat in order to avoid
tempering of the gear teeth. Figure 1 illus-
trates the impact that carbon can have on
Looking for a
the weldability of steels. The actual business partner
assembly is compared to a “mock-up” in gear tooling?
assembly machined from 1018 steel.
premium quality / short deliveries
Although the 1018 mock-up welds readily competitive pricing / technical expertise
at a moderate induction preheat tempera-
ture, the actual assembly shows poor
results, as evidenced by hot-cracking and
a hard HAZ in the 0.5 percent carbon
material. The solution was to increase the
level of induction heating to improve weld
quality and reduce the hardness of the
fusion and HAZ to maximize properties in the gear industry’s smart option
service. From a design standpoint, this
assembly requires access for both the 6898 Hawthorn Park Dr. Tel 317.915.1950
laser and the induction coil, and subjects TSA America LLC Indianapolis, IN 46220 Fax 317.576.9618
the gear to potential tempering if heat is www.tsageartools.com
not controlled.
The second example is the welding of a
gear/ring assembly. In this situation the
gear material is carburized AISI 8620, and Quality Spiral Bevel Gears
the ring is an AISI 1020 equivalent. To suc-
cessfully join this pair of materials the joint to AGMA 13
area of the gear has be machined after
carburizing to remove the high carbon Overton Gear now offers Klingelnberg Spiral Bevel Gears
layer. This same approach can be accom- as a “hard cut”or lapped gear set up to 85” in diameter.
plished by applying a stop-off to prevent
caburization. Figure 2 illustrates a success-
ful weld penetrating 7 mm. Also shown in
figure 2 is another application in which the
carburized layers were not removed at the
joint, resulting in a weld with significant
porosity and cracking.
When designing for laser welding it is
beneficial to explore material options which
minimize carbon, yet have the required
service properties. If medium or high car-
bon steel are required for the application
they may be accommodated by utilizing For smooth and quiet operation with 30% increased load carrying
additional heating and/or the use of filler capacity capable of pitch line velocities in excess of 20,000 ft./min.
materials. As the applications become Ask about our Gleason bevels up to 100”.
more difficult because of material require- 530 Westgate Dr. • Addison, IL 60101
ments, it is necessary to design for mini- Overton Gear (630) 543-9570 • Fax: (630) 543-7440
[email protected]
mal restraint, maximum access, and to & Tool Corporation www.overtongear.com
produce full penetrating welds.

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 25

 ALLIED SINTERINGS, INC.

AS AN ESTABLISHED EXPERT IN MINIATURE

POWDER-METAL GEARS, THIS COMPANY
HAS SPENT 46 YEARS FOCUSING ON THE
PROSPECT OF “INFINITE SMALLNESS.”
By Russ Willcutt

26 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

A
llied Sinterings is a company with an appetite for goods markets, probably 60 percent of its products
success, which is perfectly in line with its physical are incorporated into medical devices. One reason the
origins. “We started out in a converted diner out company’s gears and related parts are so well-suited
on Route 7,” Mark Foster, who is the company’s for these devices—in addition to P/M’s inherent corro-
president, says with a laugh. “My father, Gifford sion-resistant properties—are their size. “You’ve got to
Foster, and his partner, Axel Madsen, wanted to start a remember that the largest part we make is what would
company that would make miniature powder metal gears, be considered small by the rest of the industry,” Foster
so they located the property, bought it, and founded the points out, “so all of our design and production efforts
company here in Danbury, Connecticut, in 1959.” are trained on miniaturization and precision.”
Forty six years later the company is still in the same The P/M process also complements prototyping for
town, but in a different site, thanks in part to the state’s high-volume production runs. “We’re achieving some
purchase of the original property when it planned to relo- very good outputs, especially in the area of miniature
cate Route 7 in 1990. “We decided to take it as an planetary drives—for example, up to 120 diametral
opportunity to grow the company, so we found a place pitch gears and planetary drives, which I see as untapped
that roughly doubled our size,” Foster says, adding that markets we’ll be focusing on,” he says. “We’re able to
Allied Sinterings now has some 16,000 square feet of provide our customers with net-shape parts, and fairly
manufacturing space and employs 35 people. inexpensively—which is good since low-cost solutions
The original concept for the company was fairly sim- are on everyone’s mind these days.”
ple. Foster’s father and his partner had taken a close Another point in which Foster takes pride is that, to
look at the evolution of manufacturing in the United a ver y great extent, sintering is a remarkably “green”
States and realized that “things needed to be made to process. “We generally use 99 percent of the material
fit in smaller spaces, basically, so they decided to that’s in the mold,” he says, “and the byproducts of
carve out the company’s niche as a P/M house spe- pressing and sintering are basically hydrogen and
cializing in miniature parts,” he says. “Our motto, in nitrogen. Plus we’re always working to improve the
fact, is that ‘It’s in the little things that we do.’” process and to stay on the leading edge of technological
One company that was attracted to Allied Sinterings advances in the industr y.”
in the early days—and which was crucial in helping build One way it goes about this is by being an active mem-
its finances as well as its reputation—was Polaroid, ber in the Metal Powder Industries Federation, and also
which found the tiny, precision P/M gears ideal for its by staying on top of its ISO certification: Allied Sinterings
popular line of affordable cameras. Since that time the was the first supplier of P/M parts to achieve ISO 9000
company’s customer base has grown considerably, and certification.
not only in terms of the numbers but its geographic As for foreign competition, Foster says he’s not much
footprint as well. “We export a great deal of product to worried. “We’re making penny parts now, and I don’t
China and other areas in the Far East,” Foster explains, think they want to make them for fractions of a penny,
“with some also going up into Canada and down into so that’s an advantage for us. But our focus is sort of
Mexico. And we have four different groups of manufac- the inverse of most manufacturers,” he says. “Many
turer’s reps working for us here in the States.” people choose to think about infinite ‘bigness,’ but we
Although the company ser vices the aerospace, like to think that there’s infinite smallness, too, so
aftermarket automotive, and industrial and consumer that’s really where we fit into the whole picture.”

FOR MORE INFORMATION:

For more information on Allied Sinterings, Inc., call (203) 743-7502 or send e-mail to [email protected].
Go online to [www.alliedsinterings.com].

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 27

 CASE
STUDY H ow does a small private job shop work its way into a pre-
mier hard finishing shop? As Nixon Gear approaches its
90th birthday—with 36 of those years focused on gear
grinding—it just may have become one. The following is the
history of gear grinding at Nixon Gear and some of what

HARD TURNING AT
we’ve experienced and learned along the way.

Beginnings
In 1920, George Nixon founded Nixon Broach and Tool Company

NIXON GEAR
with the intention of selling general machining and special tooling.
The company drifted into gear making, and by 1924 it had
changed its name to Nixon Gear and Machine. Beginning in a
small building, in what was then central Syracuse, New York, the
company prospered and eventually built three more buildings, with
the latest climate-controlled building completed in 1992.

By Sam Haines and Ron Wright

Lucky Decisions
The late sixties and early seventies saw a major shift in the business
machine segment of the gear market, from cut steel gears to pow-
dered metal and plastics. The company struggled to turn around, and
in 1977 Gear Motions purchased the assets of the nearly defunct
company. Nixon Gear had already bought its first gear grinder in
1969, and the new ownership decided that focusing on this market—
high precision and high speed ground gears—and investing heavily in
state of the art equipment would become the new strategy.
Why did we decide to grind gear teeth? There are many benefits
to grinding, including improved quality and finishes resulting in
lower noise levels and longer life cycles. The quality attained by
pregrind hobbing, heat treating, and gear grinding is markedly
improved over finish hobbing (or hob and shaving) and heat treat-
ing. While considering all of the values of a heat treated gear, one
must also consider the drawbacks.
A gear that is heat treated distorts. This distortion may
decrease the quality level of the gear elements—lead, profile,
runout—by one to three levels. Therein lies the beauty of grinding:
Not only can the gear be restored to pre heat-treated quality levels,
it can also be improved to several quality levels higher.
We believe the decision to focus on ground gears was a good
one. Since then the company has grown about five times, and in
2005 expects to ship well over $10 million in gears, those primari-
ly being high speed hardened and ground gears.
Our early gear grinders—although a step up in quality from
hobbing and shaving—required long setups. One of the reasons
for this was that threaded grind wheel dressing was time con-
suming. A single point tool was used, therefore the accuracy of

28 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

WELL-KNOWN FOR ITS HARD FINISHING CAPABILITIES, NIXON GEAR—
A MEMBER COMPANY OF GEAR MOTIONS—OUTLINES ITS EVOLUTION
TOWARD EARNING A REPUTATION FOR EXCELLENCE.

the profile form on the wheel was directly affected by the number
of passes taken.
The company bought Reishauer AZAs in the early eighties, and
with these new machines a newer technology in dressing emerged.
Instead of using a single point tool, the machines were equipped
with a motorized dresser utilizing two diamond coated discs—one
disc for each tooth flank. Dresser setup and wheel dressing times
dropped from hours to minutes.
In 1987 it bought one of the first electronic threaded wheel
grinders in the country: the Reishauer RZ300E.

Evolving Strategies
This early electronic machine was instrumental in solving gear
noise problems for high speed gear sets, particularly air compres-
sion applications, which later led the company into vacuum, air
conditioning, and super charger applications. All require significant
quality and profile geometry control for noise reduction. The advan-
tages of this machine over its predecessors included electronic ABOVE: Fellows-Reishauer #12 and Reishauer ZB
indexing—index change gears were no longer required—and the BELOW: Fanuc Robot M-710iB45
ability to produce AGMA Q15 quality levels.
In the early days the company had a solid foundation in the Mil
Standards from their IBM and Xerox days. By adding SPC in the
early nineties and putting the processes and procedures in place
to achieve ISO 9002 registration in 1996 (9001:2000 in 2002),
the company continued to press the quality envelope while adding
advanced technology.
Since 1992 Nixon has spent more than $12 million on new equip-
ment and infrastructure, with $3 million of that coming in the last two
years for what might be one of the most modern hard gear finishing
departments in the country. Gear grinders purchased during this peri-
od were Reishauer’s Rz301s, Rz362A, Rz400, and Gleason’s
Tag400. These machines ground gears that approached—if not
equaled—the quality level of the Rz300E while achieving two to three
times the productivity. Grind wheel technology also improved during
this period, allowing us to grind faster while avoiding grinding burns.
In 2002 the company found itself involved in two major pro-
grams, each requiring significant process capability. Because of an
earlier investment in automation for hobbing the company under-
stood that automation not only adds cost reduction possibilities,
but also potentially improves process capability over running manu-
ally loaded machines with many different operators.
Because of the volumes of gears we were grinding, and because
of the positive cost and quality results of our automation, the deci-
sion was clear that we would buy our first automated gear grinder.
Our choice for automation would be a Fanuc M-710iB45 robot. In

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 29

our business we see a wide variety of
sizes and shapes of gears, and because
programs may come and go, we felt that
we would have the greatest flexibility for
any program with minimal changeover cost
by going robotic.
One of the first noticeable improvements
using robotics in grinding, and particularly
on the smaller gears, was the average
floor-to-floor time. We saw about a 2-3:1
increase in pieces per hour produced.
Some was due to reduced grinding time,
but much of the gain was from reduced
change time and increased efficiency.
Robots don’t get tired, and they work
through lunch. Of course, this allows our
people to become cell managers rather
than operators. Their energies are saved
to come up with creative ways to improve
processes and reduce costs. We also real- Hardinge Quest 8/5ISP
ized the same productivity improvement on
larger gears. In these cases, machine time
would be a larger factor.
Part of the discipline that makes robot- Size Sometimes Matters
ics work and achieve another level of quali- Let’s not forget that there are large parts, small volume, and prototyping needs out there,
ty is workholding that will work the same, so in 2001 Nixon’s sister plant, Oliver Gear, installed the Höfler 700.
time after time, every time. Company engi- This very flexible, vitrified wheel, form gear grinder with on-board gauging has been the
neers worked with Matrix Design and answer for developing special profiles for customers who want to send parts back and forth
Reishauer to develop tooling for the robot for development during the early design phases of a project. The Höfler sets up in a flash
and machine. Because the machine and and can develop custom customer profiles quickly without having to leave the machine.
the robot had to handle parts from 1-13”, Having a “development component” in the hard finishing service has been an important
special consideration was given to the part of the equation for Nixon customers. Even existing customers with mature designs
design phase of workholding tooling. can experiment with gear geometry for very minimal tooling and setup costs.
Within 18 months of full operation of Of course, there are those customers that sometimes design parts that are just a little
the first robotic, hard finish cell capacity too big, or need special tooth forms or pitches. This is not a problem for this form wheel
was already being strained as workloads machine. It can take a standard wheel and have it dressed and ready to go in under 30
increased month after month. It was time minutes, normally.
to make another big decision. We consid-
ered temporary used equipment, job-out
work, or stepping up to another $1.5-mil- Different Strokes
lion robotic grinding cell. In the end it was
an easy decision. Only by holding fast to
Getting good hard finished gears means
producing good blanks. All the technology “WHY DID WE DECIDE TO GRIND
the strategy of core competency invest- in the world is wasted without careful,
ments could the company continue to precise development upstream. GEAR TEETH? THERE ARE MANY
improve the process. Traditionally, ground gears will get some
And improve it did, although at first it combination of bore grinding, OD and/or BENEFITS, INCLUDING IMPROVED
seemed like it would be hard to improve surface grinding to true up faces and
much. The same gear grinder model would insure that the final product runs true. QUALITY AND FINISHES, RESULT-
be used, and after much discussion about Over the last five or 10 years Nixon
a one size smaller robot, it was decided to has developed hard finishing on its better ING IN LOWER NOISE LEVELS AND
stay with “greater flexibility” for part han- CNC lathes and special-purpose boring
dling, and the same 45Kg (99lb) robot was machines using carbide and ceramic tool- LONGER LIFE CYCLES.”
ordered. What changed the most was a ing. One of the problems we’ve faced in
new parts handling system that held vastly these machines was holding the tighter
greater numbers of parts in significantly bore tolerances—not because the machines weren’t capable so much as they didn’t have
less floor space. Denser parts handling the resolution for the fine-size adjustments needed.
also meant we could run our first “lights With the introduction of robotic gear grinders it soon became apparent that the process of hard
out” shift; a concept we could have only finishing could be greatly improved with a more flexible and dedicated hard finishing machine. The
dreamed about in 1969. company chose a Hardinge super-precision lathe to feed both of the robotic gear finishing cells.

30 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

 Future Trends
As we have discussed, gear grinding has come a long way since we
obtained our first grinder in 1969. Setup and cycle times have got-
ten much shorter. Quality levels attainable in AGMA 200-A88 terms
have reached Q15 as needed, and Q13 or higher in production.
Productivity and quality have been enhanced by the use of
automation. Improvement in accuracy and repeatability of fixtures,
and the development of expendable tooling, including gear grind
wheels, add increased “process capability.” Meanwhile, microcrys-
talline ceramic abrasive wheels help control the delicate balance
between material removal and high surface finishes while control-
ling grinding burns.
The improvements in time, quality, and costs we’ve mentioned
have made grinding a practical, cost-effective process when com-
pared to finish hobbing (or hobbing and shaping), particularly when
heat treating is required. What is the future of gear grinding?
Whatever it turns out to be, Nixon Gear will be at the leading edge
of developing technologies.

ABOUT THE AUTHORS:

Sam Haines is president, and Ron Wright is development engineering
manager at Nixon Gear—a member company of Gear Motions. To
learn more call (315) 488-0100 or go to [www.gearmotions.com].
Hofler ZME 402 CNC Gear Analyzer

SINTERED
METAL PARTS

THE RARE COMBINATION OF SMALL INTRICATE POWDERED

METAL PARTS AND WORLD CLASS MANUFACTURING

Over 45 Years
of Customer
Satisfaction

GEARING •• Specializing
AGMA Quality 8 Can Be Guaranteed
in Fine Pitch Gearing – 120 Diametral Pitch

ALLIED SINTERINGS, INC.

29 Briar Ridge Road • Danbury, CT 06810 • TEL: 203.743.7502 • FAX: 203.743.2538
TOLL FREE: 1.877.875.0464 • www.alliedsinterings.com

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 31

ASP STEELS—NOW PRODUCED BY THE NEWLY DEVELOPED DVALIN PROCESS—
FROM ERASTEEL HELP USERS MANUFACTURE EFFICIENT, LONG-LASTING, PRECISION
MACHINE TOOLS. By Lars Taflin

In
many of today’s applications for powder metallurgical from their already extremely low levels by another 90 percent, with
steels, the requirements on the material increase consis- a concomitant increase in fracture strength of 20 percent. With a
tently. Tool users are seeking improvements to achieve stronger and cleaner material, the performance of tools and com-
increased cutting speeds and feed rates, greater reliabili- ponents in many situations—especially under severe operating
ty, longer life, better tolerances, and finer surface finish. conditions—will improve, not least for gear cutting tools.
These in turn call for better substrate materials to be able to opti-
mise parameters and enhance ultimate tool performance.
In the early sixties Erasteel—the world’s leading high speed ASP Production
steel supplier—pioneered the development of powder metallurgical ASP steels are produced through exposing molten steel with nitro-
high speed steels. These are known under the registered trade gen gas jets, forming small spherical droplets, which then solidi-
name of ASP®. Their outstanding combination of high hardness, fies into powder. After cooling, the powder is put into capsules
uniformity of structure, and excellent strength has given the materi- before being hot isostatic pressed to full density. This process
al the justifiable reputation of an excellent substrate material for ensures a homogenous distribution of alloying elements and
many kinds of tools. Gear cutting tools such as hobs, shaper, and results in a uniform distribution of small carbide particles.
shaver cutters are among the many and varied applications of ASP.
Erasteel’s latest improvement in the manufacture of ASP is iden-
tified as the DVALINTM process, after the Norseman who crafted the Non-metallic Inclusions in PM-HSS
famous sword “Tirfing” used to win many glorious battles. This The critical properties of hard materials like high speed steels
new development reduces the content of non-metallic inclusions (HSS) are controlled by the larger imperfections in the material.

32 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

Tensile strength, impact toughness, and fatigue resistance are all the material properties. These carbides and carbide segregations
limited by these larger imperfections and, when in critical positions are the main limiting factors for the mechanical properties of the
in a tool, they can cause failure. Efforts to improve the perform- material, but also normally for the tools made of it. In the late six-
ance of hard materials necessitate the study of these imperfec- ties the limitations in strength, impact toughness, and fatigue
tions through detailed evaluation of inclusion/carbide size and dis- resistance of the HSS were the main reasons for the development
persion. With such an evaluation in hand the view is to eliminate of the powder metallurgical (PM) process for the manufacturing of
imperfections entirely or, more realistically, reduce their frequency high-speed steels. The PM route brought tremendous improve-
and, most particularly, their size. No matter whether the imperfec- ments to the properties of the high-speed steels as a result of
tion is present in the body of the material or on the tool surface, it fine carbides with a homogeneous distribution. Tensile strength,
is the size of any imperfection in a critical position that limits the impact toughness, and fatigue resistance improved due to the
material strength. A non-metallic inclusion present in the finished reduced size and amount of critical crack initiation points in the
tool surface can lead to premature failure in the same way as a gas-atomised ASP steels.
surface imperfection caused by poor grinding. After some years of use, it became clear that the imperfections
High-speed steels have a high content of carbon, tungsten, limiting the mechanical properties of PM-HSS were not large carbides
molybdenum, and vanadium. These elements form carbides, which or segregations of carbides—like in the conventional HSS—but by
are essential to give the hardness and, even more, the wear non-metallic inclusions (NMI), typical for all types of steels. Their dis-
resistance expected from the steel in use. However, during the tribution and size can affect the mechanical performance of the steel
solidification of conventional high-speed steel, larger carbides and and tools through the same mechanism as larger carbides or carbide
carbide segregations are also being formed, to the disadvantage of segregations by acting as stress raising crack initiating points.

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 33

 FIGURE 2 Improvements of bend strength, comparison with
conventional M42

In the nineties Erasteel developed and introduced the process of

THE ASP PROCESS electro slag heating (ESH) at its plant in Söderfors, Sweden. ESH
enabled heating the steel in a large tundish.
This new process step rendered a massive 90-percent reduction
in the number of NMIs present in the ASP grades.
Despite these major improvements, ongoing evaluation of ASP
grades and tool performance showed that the mechanical proper-
ties were likely to be improved if the level of NMI could be reduced
even further.
In a project that Erasteel star ted in 2002, the non-metallic
inclusions were studied in detail: how and where they were being
formed, and where they grew in the process chain. The sources
to the NMI have now been eliminated/minimised through innova-
tive technical improvements, and the whole production chain fol-
lows best possible practice, based on the material proper ties
achieved. The new process to produce ASP steels has been
given the name DVALIN.
Compared to the earlier generation of steels, depending only
upon ESH, another 90 percent of the non-metallic inclusions have
been removed with DVALIN. This has added 20 percent to the frac-
ture strength of the ASP steels, contributing significantly to the per-
formance for tools in terms of reliability, feed rate, tool life, and
high finish surfaces, etc. (See figures 1 and 2.)
Note: When using the latter generation of tool materials with
refined microstructure, the surface finish becomes of great impor-
tance to maximise the performance of various tools. Improvement
FIGURE 1 Reduction of non-metallic inclusions, PM from early of tool surfaces is definitely one potential area of improvement,
seventies, ESH from mid nineties, DVALIN at present
especially in combination with for instance PM-HSS.

34 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

 In many applications, tools or components operating under condi-
Benefits with DVALIN tions of oscillating loads make severe demands on the fatigue resist-
For high performance cutting tools such as hobs, broaches, end mills, ance of the PM-HSS. DVALIN answers all these questions owing to its
and taps, it can be the homogeneity and cleanness of the steel that enhanced fatigue strength consequent of the low level of NMI and
make the difference between success and failure of a tool. fine carbides distributed optimally throughout the ASP grades.

FIGURE 3 Weak point at an inclusion, causing tooth breakage FIGURE 6 Less inclusions, higher fatigue strength

In other types of applications, such as cold work tools or compo- What are Non-Metallic Inclusions?
nents, the very fine carbides and low level of NMI distributed All steels contain more or less non-metallic inclusions (NMI) deriv-
throughout the homogeneous structure of ASP may become highly ing from scrap, ferro-alloys, or the general melting environment.
beneficial. Along with good grinding and polishing techniques by Although it is accepted that, as NMIs are less dense than the
our toolmaker customers, the material contributes to the provision molten steel, many will simply float to the surface during melting
of tooling with a near mirror-like finish and extended working life. and be discarded as part of the slag, but a number can remain in
the molten steel. In order to stimulate the removal of these
remaining NMIs, processes such as argon bubbling or electromag-
netic stirring can be introduced during melting. Another alternative
is to carry the entire melting process through under vacuum.
Whatever technique is applied, the manufacture of “clean steel”
demands tight control of the melting process.
With reference to the American standard ASTM E45, non-metallic
inclusions can be divided into: A) Ductile; B) Brittle; C) Brittle Ductile,
and; D) Un-deformed. Each group is then further subdivided on seven
levels based on the number of inclusions. The A-inclusions are often
sulphides like MnS and they deform with the steel during forging,
rolling, and other forming operations. B-, C-, and D- inclusions are
oxides of different analysis. Aluminium, silicon-calcium, and titanium
FIGURE 4 Pit after an inclusion that has fallen out
are some of the element found in these groups. B-inclusions are brittle
and crack up to a rather harmless configuration during the metal form-
ing process. C- and D-inclusions are more severe since they deform
very little or not at all, and thus stay as large crack initiation points.

Conclusion
By consistent investigation and ongoing process development, the
Erasteel PM-HSS grades, ASP, have reached unprecedented levels
of cleanness. The DVALIN process allows the production of the
purest PM-HSS powders available globally and assists our cus-
tomers in manufacturing long lasting, reliable, and maximum pro-
FIGURE 5 Smooth surface without weak points ductivity tooling.
* ASP® is a registered trademark of Erasteel

ABOUT THE AUTHOR:

Lars Taflin is ASP product manager at Erasteel. To learn more go to [www.erasteel.com].

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 35

 LAYOUT
GUIDES
PART 1: Straight Bevel Gears
THIS SERIES IS INTENDED TO PROVIDE DESIGN ENGINEERS WORKING ON RIGHT ANGLE GEARED APPLICATIONS
WITH THE KNOWLEDGE NECESSARY TO FURTHER THEIR WORK IN-HOUSE WITH MINIMAL INPUT FROM INSIDE OR
OUTSIDE GEAR SPECIALISTS. By Russell Beach

T
his is the first of a three-part series of instructions to assist compared to the requirement. This can be an iterative procedure
engineering designers and detailers with the process of cor- involving several sizing trials before a dimension sheet is finalized.
rectly laying out bevel and hypoid gear teeth. Each guide Taking the data listed on a gear dimension sheet and converting
assumes that the basic gear tooth design information is it into a drawing is the key next step. It is the connecting step
already at hand (for straight bevels this would include shaft between the gear tooth design and the creation of the rest of the
angle, pinion and gear pitch diameters, outer cone distance, face mechanical structure—the gear blank, its bearing arrangement
widths, pinion and gear pitch angles, face angles and root angles, and, ultimately, the housing itself. It is the critical step leading to
and the pinion and gear outer addendums and dedendums). This correctly produced gear-part drawings.
basic information is usually available in the form of a gear “dimen- Straight bevel gears are the simplest form of bevel gears. A
sion sheet,” which may have been calculated by your own gear engi- comparison can be made to spur gears, which also have straight
neer. Nissei, as a gear design and manufacturing teeth. Whereas spur gears are char-
THE LAYOUT GUIDE SERIES WILL PRESENT:
company, provides gear dimension sheet infor- acterized by straight teeth on an
Part I: Straight Bevel Layout Guide
mation to our customers as part of our service. imaginar y pitch cylinder, straight
Part II: Spiral and Zerol® Bevel Layout Guide
Publications on the subject are also readily avail- Part III: Hypoid Layout Guide bevel gears are characterized by
able from the American Gear Manufacturers teeth of tapering depth on an imagi-
Association (AGMA) or from The Gleason Works. nar y pitch cone. Spur gears can be theoretically represented by
To create a dimension sheet certain information is usually two tangent cylinders rolling together without slipping. In a simi-
required. This information for straight bevels includes the applied lar way, straight bevel gears are represented by two tangent
loads, speed, shaft angle, gear materials, heat treatment, lubrica- cones rolling on each other without slipping.
tion method, operating temperature, required life, and operating Step one in drawing a bevel gear set is to lay out the pinion and
conditions affecting the driving and driven loads. For straight gear axes at the desired shaft angle. The vast majority of bevel
bevels an initial size with pitch, face width, and tooth pressure and hypoid gears are designed for a shaft angle of 90 degrees,
angle is chosen and the bending stresses and contact stresses for which we will use for our examples. The intersection point of the
the resulting design are calculated. The resulting estimated life is axes is the “pitch apex.”

36 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

 Construct a normal to the pitch line through the pitch point. This
locates the heel end of the teeth. Construct another normal at a
distance along the pitch line equal to the face width to find the toe
end of the teeth.

The next step is to locate the “pitch line,” drawn as an exten-

sion of the common tangent cone element, for the gear set. The
angle between the pinion axis and the pitch line is the “pinion
pitch angle,” and the angle between the gear axis and the pitch
line is the “gear pitch angle.” The sum of the pinion pitch angle
and the gear pitch angle is the “shaft angle.”

On the normal at the outside, measure off the gear and pinion
outer addendums and also the gear and pinion outer dedendums
as shown in the following diagram.

Next, locate the pitch point along the pitch line at the dimension
given for the outer cone distance. This point simultaneously identi-
fies the pitch diameter for the pinion and for the gear.

From the pinion outer addendum and at the given pinion face
angle, draw a line connecting the normal at the heel to the normal
at the toe. You now have the pinion face surface for the blank.
Likewise draw a line, at the gear face angle, from the gear outer
addendum connecting the heel and toe normals to establish the
gear face surface. In the same way, draw lines, at the pinion and
gear root angles, from the pinion and gear outer dedendum points,
connecting the normals to create the pinion and gear tooth root
lines. Notice that the teeth taper in depth from the heel to the toe.
These root lines, when extended, should cross the axes at the
pitch apex, forming a depthwise taper known as “standard depth-
wise tooth taper.” The root apex and pitch apex for standard taper
designs, then, are coincident. Standard taper is used for all
Gleason-type straight bevel gear designs (with the exception of the

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 37

special case of Revacycle differential gears). The construction It is not uncommon to see blanks with design changes that length-
should also demonstrate another characteristic of bevel and hypoid en the root face width compared to the theoretical form. There are
gears in general: parallel clearance. The root line of one part manufacturing limitations with straight bevels to watch out for. The
should lie parallel to the face line of the mating part. root-land slot width taper can become excessive if the face width
exceeds 25 percent of the outer cone distance. “Excessive slot
width taper” occurs when the outer slot width is more than twice the
inner slot width. Consequently the overlapping top and bottom cutter
blades, which individually must be smaller than the smallest slot
width to prevent mutilating the tooth flanks, can leave a “fin” of
uncut material in the root. The cutting tool life can also suffer due to
the uncut material rubbing on the back edge of the blades.

With the standard theoretical form of the teeth now correctly

identified, it is possible to start detailing the rest of the pinion and There is another caution when making blank form changes, one
gear blank. Note that the traditional (non-FEM) gear rating calcula- that is related to the practice of drawing the pinion and gear inde-
tions are generally always based on this theoretical form. pendently. When introducing changes to the standard theoretical

38 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

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gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 39
 form, the pinion and gear teeth should be localized tooth contact is placed “central
drawn together to judge the effect on the toe” on both pinion and gear. If the local-
mutual tooth contact position. In the fol- ized tooth contact was placed central toe
lowing example, the blanks are trimmed on this example pinion member, the con-
and the mating of the teeth results in a tact would run off the ends of the gear
contact pattern placement dilemma. The member teeth. This is generally undesir-
pattern is in the middle of the pinion face able for reasons of noise, vibration, and
width, but on the toe end of the gear face load concentration.
width. The contact placement issue for this We hope this article has been helpful for
gear set was not discovered until the parts the design of your bevel gear sets.
were manufactured and run together in the Hopefully you can now move forward with
test machine. the rest of your application design and
The potential for the occurrence of this communicate your needs more effectively
mismatch is not readily apparent if the with your gear suppliers. Part II of the
gear and pinion are drawn separately. The series, on spiral and Zerol® bevel gears,
mismatch results in poor positioning of will appear in next month’s issue of Gear
the load on one member. Usually the Solutions magazine.

APPENDIX:
Bevel Gear Terminology
Note: The tooth taper in this drawing is shown for the general case where the root
apex does not coincide with the pitch apex. In the case of straight bevel gears
which have “standard depthwise tooth taper,” the root angle is such that the root
apex and pitch apex coincide.

ABOUT THE AUTHOR:

Russell Beach is a mechanical engineer with more than 20 years of experience in gear design specializing in spiral bevel and hypoid gear
design, noise and failure analysis, and troubleshooting. Nissei is a leading manufacturer of OEM parallel axis and right angle gearing
components and the GTR brand of gear motors and speed reducers. Questions regarding this article can be sent to sbquestions@
nissei-usa.com. Go online to [www.sb.nissei-usa.com].

40 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

 try standards,” Kwiatkowski says. become much more. Today, ISO 9001 is
industryNEWS << from page 19
A nationwide network of industrial bear- helping thousands of companies worldwide
system helps Bunting achieve continuous ing distributors, metal service centers, manage their processes to become more
performance improvement and produce regional service centers, warehouses, efficient and cost-effective.
greater results. direct sales personnel, and well-trained To learn more go to [www.buntingbearings.com].
“As customers continue to become more Bunting Bearings sales representatives
sophisticated and need specialized solu- provide customers with expert innovative ATS Appoints Gerald A.
tions for their equipment needs, Bunting solutions for specialized design and prod- Hooper to Board of Directors
continues to commit to quality through the uct requirements. ATS Automation Tooling Systems, Inc.,
ISO 9001:2000 certification program,” Established in 1855, Bunting Bearings has announced the appointment of Gerald
says Bunting’s president, Tom Kwiatkowski. Corp. has manufactured bronze, plastic, A. Hooper, FCA, to the company’s Board
“Through this quality management program, powdered metal, aluminum bearings, and of Directors. He will also ser ve on the
Bunting has increased consistency in its solid bars to the industry with superior quali- company’s audit and finance committee
products and services, reduced waste and ty and service. Bunting Bearings Corp. com- of the board.
product failure, and increased productivity bines into one source the experience gener- Hooper is chairman of the board of The
of its resources.” ated by nearly a century and a half of pro- Economical Insurance Group, one of the
Bunting has benefited from its expertise ducing products for industry: experience that largest property and casualty insurers in
in the bronze industry and over 150 years today encompasses all the latest principal Canada. He recently retired from a distin-
of quality manufacturing. “We are commit- production processes. guished 19-year career at Schneider
ted to continuing our progress and growth ISO 9001 was founded in 1987 as an Foods—a leading producer of premium
by demonstrating through this quality certi- internationally accepted quality manage- quality food products—where he served
fication that our recent investment in facil- ment certification system to define, identi- as executive vice president and chief
ities and processes produces products fy, and confirm quality benchmarks within financial officer, as well as a member of
and service will continue to exceed indus- organizations. But since then it has the board of directors of Schneider

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Corporation. Prior to joining Schneider Foods, Hooper was a partner at what is now Four different B models offer one- to
KPMG. He has been a chartered accountant since 1970 and was named a fellow of the three-ton lifting and include a one-year war-
Institute of Chartered Accountants of Ontario in 2003. Hooper is also actively involved in ranty on parts and workmanship. The new
Kitchener-Waterloo where he serves on a number of community boards and committees. B series motor is also available separately,
“Gerry brings over 30 years of financial, strategic, operating, and governance experi- and can be easily installed on existing My-
ence to ATS, and we are confident that his unique skills and substantial knowledge will te single-phase winch hoists.
add even greater depth and expertise to our board,” says Larry Tapp, chairman of the To learn more call (317) 897-9880 or
board of ATS. “We believe Gerry will make an outstanding contribution to ATS for many (800) 840-9880. Send e-mail to
years to come.” [email protected] or go to the company’s
Hooper joins an experienced board that includes Tapp, former dean of the Richard Ivey Web site, [www.myte.com].
School of Business; William Biggar, managing director of Richardson Capital Limited;
Richard Campbell, president of Seacoast Consulting and a former senior executive of Horton Hires New VP of
Black & Decker; Rober t Ferchat, retired chairman and CEO of Bell Mobility; Peter Janson, Quality Assurance
former chairman and CEO of the Nor th American Operations of AMEC, Inc.; Rober t Luba, Horton Holding, Inc., has hired Jeff
president of Luba Financial, Inc., and previously president and CEO of Royal Bank Blankenship as vice president of quality
Investment Management; and Ron Jutras, president and CEO of ATS. assurance. He will oversee Horton’s
For more information call (519) 653-6500 or go online to [www.atsautomation.com]. Warranty and Field Service group, quality
functions in all plants, and the company-
New My-te B-Series Winches wide “Lean Six Sigma” efforts.
Maximize Lift Control and Safety Blankenship has 28 years of experience
Further improving the well-known reliability of its 115-volt, single-phase winch hoists, My- in automotive and recreational vehicle
te® Products, Inc., is introducing its new B-series models that include a motor equipped industries. Most recently, he was director of
with a physical disc brake. quality, Six Sigma and Lean Production at
Already designed with self-locking worm gear reduction for positive load holding and a Bombardier Recreational Products in
dynamic brake circuit for instant stopping, the new B-series’ motor brake completes a Sturtevant, Wisconsin, for the company’s
triple brake redundancy system that enhances overall braking power and provides outboard engine manufacturing plants.
optimum load control for lifting and spotting. All together, the B-series stands among the Bombardier Recreational Products manufac-
industr y’s safest material-handling lifting devices. tures snowmobiles, watercraft, sport boats,
and all-terrain vehicles for global markets.
“We’re pleased to have an experienced
manufacturing professional with a strong
Equipped with a triple brake redundancy system that
includes a physical motor brake, My-te’s new B-series track record in continuous improvement
stands as one of the safest and most economical one- to
three-ton, single-phase winch hoists available. and quality assurance joining Horton,”
says Randall Nord, CEO and president of
Horton. “His expertise will help challenge
our staff to develop optimal solutions for
our customers.”
Previously Blankenship was operational
excellence leader for United States and
Canada operations of Tower Automotive in
Novi, Michigan; director of manufacturing
support services for RWD Technologies,
Inc., in Dearborn; and director of supplier
development for International Truck and
Engine Company in Westchester, Illinois. He
also worked for almost a decade in various
quality management roles at Honda, includ-
ing three years in Japan. Blankenship is cer-
tified by the American Society for Quality as
a Six Sigma Black Belt. He received a bach-
elor’s degree in political science from Ohio
University in Athens, Ohio.

42 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

 With more than 50 years of industry expe-
rience and a commitment to service, reliabili-
ty, and innovation, Horton is a premium
worldwide provider of fan drives, fans, and
wire form products. Horton’s comprehensive
research and development processes are
driven by a dedication to exceed the industry
requirements today and in the future. The
company has manufacturing plants in the
United States and Germany, with a licensed
manufacturing facility in Australia and sales
offices in the United States, Germany,
Mexico, Brazil, and Australia.
For more information call (888) 813-9926
or send e-mail to [email protected]. Visit
the Web site at [www.hortonww.com].

Abstracts being Accepted

for INTERTECH 2006
The Industrial Diamond Association has
announced that it’s accepting abstracts for
the INTERTECH 2006 International Diamond
and CBN Conference to be held in Atlanta,
Georgia, April 24-26, 2006. INTERTECH Makino a81M horizontal machining center
Conferences have historically been the most
comprehensive technical and application
focused conferences held on industrial dia-
mond, cubic boron nitride, CVD diamond,
polycrystallines, and other materials classi-
fied as “superabrasives.” Makino a81M Provides compressor manufacturing will all benefit
INTERTECH is unique in its format, fea- High Torque and High Thrust from the a81M.
turing technical research and development Makino’s a81M horizontal machining cen- The a81M is particularly suited for long
of superabrasives as well as the newest ter has been developed for the machining reach and large diameter boring operations
applications from notable end users in of tough and hard materials. It is ideally which require a great deal of torque, particu-
manufacturing and service industries. suited for large diameter boring and face larly at low rpm. For applications such as
Superabrasives are used to saw, cut, drill, milling on such challenging materials as tapping, where a significant amount of spin-
and machine glass, concrete, superalloys, stainless steel, titanium, titanium alloys, dle stopping, starting, and reversal occurs,
hard steels, carbide, cermets, metal matrix inconel, ductile iron, cast iron, and CGI the Makino high-torque spindle on the a81M
composites, high silica aluminum, wood, (compacted graphite iron). is significantly faster and has less idle time.
and other ferrous and non-ferrous materi- The unique high-torque and high-thrust The integral drive spindle of the Makino
als used in industries ranging from aero- spindle on the a81M provides unparalleled a81 greatly outperforms all other spindles
space, mining, electronics, medical, productivity and reliability for a machine of on the market due to the nature of its effi-
drilling, and automotive to stone process- this type, which helps customers reduce cient design, which provides significantly
ing, construction, wire drawing, glass man- costs from its manufacturing operations. It higher torque at a low rpm. This proprietary
ufacturing, and woodworking. has a quick tool-to-tool time of only 1.7 design combines the optimum blend of
For additional information contact Terry seconds, with a similarly brisk chip-to-chip speed and superior rigidity necessary to
M. Kane—chairman of INTERTECH 2006 time of 4.2 seconds. take aggressive cuts.
and executive director of the Industrial The a81M has significant application in Other high torque spindles utilize a
Diamond Association—at (614) 797-2265. general machining and production machin- geared-type head. Such design intrinsically
Send e-mail to [email protected]. ing. Such specific industries as aero- causes a loss of significant power that fur-
Full conference details can be found at space, diesel engine, construction equip- ther drops spindle efficiency, which can
[www.intertechconference.com]. ment, oil field components, and pump and continued on page 50 >>

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 43

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REF#104 BARBER-COLMAN 16-16, S/N 4136, Dbl Thrd, “C” Style End
Brace w/Diff REF#105 REF#104
PFAUTER #PE-125H, 6-Axis, 5" Dia, 8.5 DP, 9.5" Max Swing, ‘88
BARBER-COLMAN 16-16 Multicycle, S/N 4170, Dbl Thrd w/Jump LIEBHERR #L-901, 35" Dia, 2.5 DP, 2-Cut Cycle, Univ Hob Head
REF#104
Cut Cycle “C” Style REF#105 REF#104
PFAUTER #PE-150, 6-Axis CNC, 6” Dia, 5 DP, 6” Face, Fanuc 18MI
REF#104 BARBER-COLMAN 16-16, S/N 4473, ’73 4-Thrd w/Workclamp LIEBHERR #L-902, 36" Dia, 25" Face, 2 DP, Crowning, ‘78 REF#104
PFAUTER #PA-320, 6-Axis CNC, 13” Dia, 3 DP, 10” Face, New ‘80 Cyl “C” Style REF#105 MODUL #ZFZW 800, 29.8” Dia, 16.25” Face, 2.5 DP Crowing, 2-
REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4520, ’75 Dbl Thrd Cut REF#104
PFAUTER #PE-500, 6-Axis CNC Gear Hobber, 13.78" Dia, 3 DP w/Gooseneck Slide REF#105 OVERTON #HD-400, 15.7” Dia, 12” Face, 3 DP, New ‘88 REF#104
REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4631, ’79 “C” Style End PFAUTER #P-400, 3 DP, 16" Dia, 11" Face, Auto-Cycle, ‘65 REF#104
RPMACHINE #SH-150/750, 4-Axis CNC Spline Hobber, New ‘05 Brace, 4W Adj Ctr REF#105 PFAUTER #P-630, 24” Cap, 2-Cut Cycle, Crowning, ‘78 REF#104
REF#104 BARBER-COLMAN AHM (36”), S/N 1152, ’42 Dbl Thrd REF#105 PFAUTER #P-750R, 8" Dia Rotors, 35" Face, 12", MINT!! ‘82
SYKES #H160, 4-Axis CNC Hobber, 6” Dia, All the Features, ‘93 BARBER-COLMAN 16-36, S/N 4090, ’66 Dbl Thrd, “C” Style End REF#104
REF#104 Brace REF#105 PFAUTER #P-900, 2 DP, 36” Dia, 15” Face, Tailstock, ‘60 REF#104

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 45

RPM #AD-616, 6” Dia, 16” Face, 16 DP, (3) Thread, NEW REF#104 FELLOWS #61, #6A, #61A, #645A, From 18”-35” Dia, 0-12” Risers HOEFLER #H-650/800, 36” Dia, CNC w/On-Board Inspection,
STANKO #5A-342, 100-160” Dia, 34” Face, .84 DP, Beautiful REF#104 New ‘98 REF#102
Piece, ‘80 REF#104 FELLOWS #7, #7A, #715 Etc, 7” Dia, 0-12” Risers, Several Avail GLEASON # 130, 36” Max Dia, CNC Curvic Cplg, Comp Reb REF#102
WOLF #GH20-11, 20” Dia, 11” Face, 3.2 DP, ‘98 REF#104 REF#104 HOFLER/NOVA, #650/800, 25” Dia, 21” Face, 1.4 DP, New ‘98
WOLF #GH32-11, 32” Dia, 11” Face, 2.5 DP, ‘98 REF#104 FELLOWS #8AGS Vert Gear Shaper, 8” Dia, 2” Face, 6-7 DP REF#104 REF#104
GEAR PINION HOBBERS & SPLINE MILLERS FELLOWS #10-2, 10” Dia, 4” Face, 4 DP REF#104 OPAL #50 CNC Form Grinder, 20.5" Dia, 24.8" Face, ‘98 REF#104
FELLOWS #10-4, 10” Dia, 4” Face, 4DP REF#104 OPAL #420 CNC Form Grinder, 16” Dia, 14” Face, 2 DP, New ‘93
DAVID BROWN, #P-40H, 40” Dia, 100” Face, 2 DP, New ‘70 REF#104 FELLOWS #20-4, 20” Dia, 4” Face, 4 DP, ‘70’s REF#104 REF#104
FITCHBURG, 40” Dia, 73” Face REF#104 FELLOWS #36-6, 36” Dia, 6” Face, 3 DP, ‘51-‘72 REF#104 OPAL #1200 CNC Form Grinder, 47” Dia, 25” Face, 1.5 DP, ‘97
LEES BRADNER #SH, 8” Dia, 54” Face, 4 DP, ‘50 REF#104 FELLOWS #120-8, 8” Stroke, Spur Guide, Rebuilt 1988, New Electrics REF#104
HURTH #KF-32A 15” Dia, 59” Face, ‘67 REF#104 REF#104 REISHAUER #RZ-801, 31” Dia, 11” Face, 3.5 DP, New ‘91 REF#104
WANDERER #31M, 12” Dia, 118” Length, Hob Head Equipped FELLOWS #200, 8” Stroke, 200” Dia Spur, Exc. Cond 1 DP, GEAR GRINDERS
REF#104 Rebuilt ‘88 REF#104
GEAR HOB & CUTTER SHARPENERS (incl CNC) FELLOWS #Horiz Z Shaper, 6” Stroke, 17” Bore in Table, New GLEASON #120 Curvic Grinder REF#100
’50’s REF#104 MAAG #HSS-30A, 11.8” Dia, Spur REF#102
BARBER COLMAN #2 1/2-2, 2.5” Dia, Straight Flute Hobs REF#102 LORENZ #LS-320, Tilt Shaper, 12” Dia, 2” Face, 4 DP, New ‘80’s REISHAUER #AZA-K, 13” Dia, SPA Diamond Disc, Taper Grinding
BARBER COLMAN #3-4/4, Index Plates REF#102 REF#104 New ’79 REF#102
KLINGELNBERG #SNC-30, 12” Dia, CNC Hob Sharp, New ’84 LORENZ #LS-320, 12” Dia, 2” Face, 4 DP, New ‘88 REF#104 SHG-360 OKAMOTO, 14” Dia, FAESSLER DSA, Crowning, New
REF#102 MAAG #SH-75C, Disc Control, 9” Stroke, Auto Stop, Exc, ‘65 REF#104 ’74 REF#102
FELLOWS 6HCS, 6” Dia, Helical Shaper Cutter Sharpener REF#102 MAAG #SH-100/140, 57” Dia., 12.6” Face, 2 DP, Internal Attachment MAAG SD32X, 14” Dia, Crowning, T&R Relief REF#102
ARTER #A-12, 12” Rotary Surface Grinder for Sharpening REF#104 NILES ZSTZ-630C3 NILES 24” Dia, Crowning, 10” Face, T&R
Sharper Cutters REF#104 MAAG #SH-180/300, Ext. Generating/Int Gashing Heads, New REF#102
BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, ‘57 ‘60’s REF#104 HOEFLER H-630E PRIMA (24”/30”) Crowning T&R relief, Double-
REF#104 MAAG #SH-250, 43” Dia., 26” Face, Crowning, New ‘74 REF#104 Flank, New ’90 REF#102
BARBER-COLMAN 10-12, 10" Dia, 12" Length, Spark Out REF#104 FELLOWS-REISHAUER #12, 12" OD, 6-3/4" Face, Dresser, Gears
GEAR DEBURRING/CHAMFERING/POINTING
FELLOWS #6SB, Helical Cutter Sharpener, 6” Dia, up to 50 Degrees REF#104
REF#104 CROSS #75, 10” Dia REF#102 HOFLER H2500/1200, 98” Dia, 47” Face, 8DP, ‘74, ISO 3-4
HEALD #22 Rotary, 13” Dia, 12” Chuck REF#104 REDIN #24, 28” Dia, CNC, Twin Spindle Deburring Mach, Yr ’90 Quality REF#104
KAPP #AS204GT, 10” Dia, Wet Grinding, CBN Wheels, ‘82 REF#102 REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#104
REF#104 REDIN #18, 20” Dia, Twin Spindle Deburring Mach REF#102 REISHAUER #AZA & #AZA-K, 11” Dia, 3 DP, 7” Face, Exc Cond
KAPP #AS-305T, 12” Dia, 28” Face, 1 DP, Mint Condition, New CROSS #50 Gear Tooth Chamferer, 18” Dia, Single Spindle REF#104 REF#104
‘80’s REF#104 CROSS #54 Gear Tooth Chamferer, 30” Dia, 18” Face REF#104 REISHAUER ZB Gear Grinder, 27 5” Max Dia, 11” Face, Good
KLINGELNBERG #AGW-30A, 11” Dia, 16” Part Length, Straight CROSS #55 Gear Tooth Chamferer, 18” Dia, 14” Face REF#104 Cond ‘70 REF#104
& Spiral Gash REF#104 CROSS #75 Gear Tooth Chamferer, 10” Dia, 10” Face, ‘52 REF#104 RED RING #SF-500 Int/Ext, 26” Dia, 30” Face, 2 DP, ’88 REF#104
KLINGELNBERG #AGW-231, Auto Hob Sharpener, 10" Dia, ‘74- HURTH #ZK-7, 11” Max Dia, Twin Spindle Gear Chamferer REF#104 RED RING #SGJ-18, 18” Dia., 9” Face, Internal Attachment, New
80 REF#104 RED RING #GCU-12, Gear Shaver, 12” Dia, Several REF#104 ‘78 REF#104
BARBER-COLMAN 2 1/2-2, S/N 16, ’66 Wet w/Auto Feed REF#105 RED RING #GCY-18, Gear Honing Mach, 18” Dia, 6” Stroke REF#104 GEAR RACK MILLERS/SHAPERS
BARBER-COLMAN 6-5, S/N 110R, ’55 Wet w/Auto Dress & Sparkout RED RING #GCX-24, 3”-24” Pitch Dia Crowning, Tailstock, Taper
REF#105 Att REF#104 FELLOWS #3X36 Rack Shaper, 3” Face, 36” Face, 4 DP, Good
BARBER-COLMAN 6-5, S/N 396, ’66 Wet w/Auto Dress & Sparkout REDIN #18, 28” Dia, 2, 3, 4 Spindle, Deburrer/Chamfer, PLC’s, Tilt Cond ‘60 REF#104
REF#105 Table REF#104 MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP
BARBER-COLMAN 6-5, S/N 433, ’69 Wet w/Auto Dress & Sparkout REDIN #20D, 20” Dia, Twin Spindle, Deburrer/Chamfer REF#104 REF#104
REF#105 SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14” Dia, 5” Face, ‘82 SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke,
BARBER-COLMAN 10-12, S/N 643R83, Wet w/Auto Dress, PC REF#104 ‘80 REF#104
Control, Fact Reb ‘83 REF#105 SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10” Max Dia,
GEAR THREAD & WORM, MILLERS/GRINDERS
GEAR SHAPERS CNC (3) New ‘96 REF#104
WERA #MC6-150, CNC, Deburrer, Chamfering and Pointing, 8” WMW HECKERT #ZFWVG, 10” Dia, 49” Length, 4, ’99 REF#104
FELLOWS #10-4/10-2, Qty 150 REF#103 Dia, New ‘88 REF#104 WMW HECKERT #ZFWG 250 X 2000, 19.6” Over Bed, 19.6” 78.7”
HYDROSTROKE #50-8, Qty 2 REF#103 Hob Length REF#104
GEAR HONERS
HYDROSTROKE #20-8, Qty 5 REF#103 LEES BRADNER #HT 12"x 36" Thread Mill, 12" Dia, 36" Length
HYDROSTROKE #FS630-125, Qty 1 REF#103 FASSLER #K-400 Internal Gear Honer, 12.6” Dia, 12” Stroke, REF#104
HYDROSTROKE #FS400-90, Qty 2 REF#103 NUM 1080 Control REF#104 LEES BRADNER #LT 9"x 54" Thread Mill, 9" Dia, 54"Length REF#104
FELLOWS #20-4, Qty 6 REF#103 MIKRON #106-02, 1.5” Dia, 3-6” Length, Single Form Worm
GEAR SHAVERS
FELLOWS #48-8Z, Qty 1 REF#103 Cutter REF#104
36” Shapers, 14” Throat Risers, 53” of Swing, Qty 3 REF#103 RED RING #GCY-12, 12” Dia, 9” Cutter-Head REF#102 J&L #12x45, Thread Grinder, 12” OD, 45” Length, Nice, ‘75 REF#104
FELLOWS #10-2 & 10-4, 1 to 4-Axis CNC, 10” Dia, 2”-4” Face, RED RING #GCU-12”, 12” Dia, 9” Cutter-Head REF#102 REISHAUER #UL-900, 9” Dia, 18” Grinding Length, ‘80’s REF#104
Rebuilt REF#104 KANZAKI #GSF-400CNC5, CNC, 16” Dia, 10” Cutter-Head ‘90 REISHAUER #US, 10” Dia, 36” Grinding Length, 46” B-C, ‘80
FELLOWS #10-4 One-Axis CNC (A/B), 10" Dia, 4" Face, 4 DP REF#104 REF#102 REF#104
FELLOWS #20-4, 4-Axis, 20” Int/Ext, Dia, 4” Face, New ‘70/’03 RED RING #GCU-18, 18” Dia, Crowning REF#102 WANDERER #31L x 3000, 8” Dia, 120” Length, ‘60’s REF#104
REF#104 RED RING #GCJ-36/60, 60” Dia, 12” Cutter-Head REF#102
FELLOWS #20-8, Hydrostroke 6-Axis CNC, 20" Dia, 8" Face, 3 DP GEAR TESTERS/CHECKERS (incl CNC)
GEAR GENERATORS, STRAIGHT BEVEL
REF#104 GLEASON 13 Hypoid Tester (2) REF#100
FELLOWS #FS-180, 3-5 Axis, 7” Dia, 1.25” Face., 6 DP, New ‘88 GLEASON #710, 10” Dia, Coniflex REF#102 GLEASON #6, Angular Bevel Tester REF#102
REF#104 GLEASON #14, 24” Dia, Coniflex w/gauges, gears REF#102 GLEASON 13, Universal Angular Bevel Tester REF#102
FELLOWS #FS-630-200, 6-Axis, 24” Dia, 8” Face, 3 DP, ‘95 REF#104 GLEASON #12, Str Bev Gear Gen, 12” Cone, 3.5 Face, ‘50’s REF#104 GLEASON #17A, 90-Degree Hypoid Bevel Tester REF#102
LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI GLEASON #14 Coniflex Str Bev Gear Gen, 12” Max Cone Dist, FELLOWS #4RL, 4” Dia, Comp Roll Checker REF#102
REF#104 3.5” Face REF#104 FELLOWS #12M, 12” Dia, Involute REF#102
LORENZ # LS-180, 4-Axis CNC, 11” OD, 2” Stroke, 5 DP REF#104 GLEASON #16 Hypoid Gear Gen, 9” Max Cone Dist, 2.75” Face GLEASON #162, 90” Dia, Universal Angular Bevel Tester REF#102
LORENZ #LS-424, 16.5" Max Dia, 5.4" Stroke, ‘90’s REF#104 REF#104 FELLOWS 600RL, 24” Dia, Roll Checker REF#102
GLEASON #114 Coniflex Str Bev Gear Gen, 7” Max Cone Dist, Please Check Our Website to View the Gear Testers and
GEAR SHAPERS 2.5” Face REF#104 Recorders in Our Inventory REF#104
FELLOWS #6 Gear Shaper REF#100 GLEASON #24A Coniflex, 1.5 DP, 6" Face, 6" Work Spindle Bore
REF#104 MISCELLANEOUS
FELLOWS #3, 3” Dia, Fine Pitch, w/Change Gears REF#102
FELLOWS #7125A, 7” Dia REF#102 MIKRON #120.1 & 132.02, 1.6” Dia, 25 DP, 50’s-60’s REF#104 CINCINNATI Avenger CNC Turning Center, Model #200MS, S/N
FELLOWS #4AGS, 7” Dia REF#102 GEAR GENERATORS, SPIRAL BEVEL (HYPOID) 3650-AMS-94-0243 w/850SX Control, 12 Position Turret, 8”
FELLOWS #10-4, 10” Dia, 4” Face REF#102 Chuck, 6” Chuck REF#100
FELLOWS #10-2, 10”Dia, 2” Face REF#102 CNC 116 Gear Generator or Hypoid Rougher w/Fanuc 161-MA CINCINNATI Avenger CNC Turning Center, Model #250MT, S/N
FELLOWS #20-8, Hydrostroke, 20” Dia, 8” Face, Yr ’80 REF#102 Control REF#100 3650-BMT-94-0218 w/850SX Control, 10” Chuck REF#100
FELLOWS #36-6, 40” Dia, 6” Face, 6” Riser REF#102 GLEASON #16, 16” Dia Hypoid Spiral Bevel Gear Generator REF#102 LODGE & SHIPLEY Profiturn 50 CNC Lathe, 176” Centers, 27”
FELLOWS #36-6 Spur/Helical, 36” Dia, 6” Face, w/Vari Helix GLEASON #116, 16” Dia, Hypoid Spiral Bevel Gear Finisher REF#102 Swing, 39” Over Bed, 7” Hole thru Spindle, Reb ‘02 REF#100
Head REF#102 GLEASON #26, 36” Dia, Hypoid Spiral Bevel Gear Rougher REF#102 HUFFMAN TRUMPF HP-105 CO? CNC Laser System w/GE 2000
FELLOWS #10-2, (10” Dia), 2” Face REF#103 GLEASON #22, 22” Dia, Hypoid Spiral Bevel Gear Rougher REF#102 Control REF#100
FELLOWS #10-4, (10” Dia), 4” Face REF#103 GLEASON #22, 22” Dia, Hypoid Spiral Bevel Gear Finisher REF#102 RIGID 5-Axis CNC Mill, 2-Spindle, Type NB125, Allen Bradley
BARBER COLMAN #10 VGS, 10” Dia, 4” Face, 4 DP, New ‘81 GEAR GENERATORS, HERRINGBONE Control REF#100
REF#104 HEALD 273A Internal Grinder REF#100
SYKES #1A, 12” Dia, 30˚ Guide and Spur Guide REF#104
FELLOWS #3-3 & #3-1, 3” Max Dia, 1” Face, Pinion Supp, High MAZAK 24” x 120” Manual Engine Lathe REF#100
SYKES #5B, 60” Dia, 30˚ Guide 8” Face, New ‘60’s REF#104
Precision REF#104 OKAMOTO ACC-124N, 12” x 24” Surface Grinder REF#100
FARREL #5B, 61” Dia, 30˚ Guide, 18” Face, New ‘50’s REF#104
FELLOWS #4A Versa, 10” Dia, 3” Face, 4 DP, New ‘70’s REF#104 KENT KGS-63AD 12” x 24” Surface Grinder REF#100
FARREL #5T, 61” Dia, 30˚ Guide, 24” Face, 2 DP REF#104
FELLOWS #4A & 4AGS, 6” Dia, 2” Face, 4DP, ’68, Ref.# Several WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 ? Swing,
REF#104 GEAR GRINDERS CNC 80” Centers, 12” Spindle Hole 50/25 Motors, 480/3 Phase, Year
FELLOWS #4AGS, 6” Dia, 2” Face, 4DP, Tilt Head Machine REF#104 GLEASON #120 Curvic Grinder REF#100 1965 REF#101

46 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

MARKETPLACE Contact Gear Solutions at 800-366-2185
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ABUNDANT MANUFACTURING, INC. Allen Adams Shaper Services, Inc. SPIRAL BEVEL GEARS
820 COCHRAN STREET • STATESVILLE, NC 28677
PHONE: (704) 871-9911 Servicing Fellows Due to customer demands, we have expanded our
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FAX: (704) 871-9961 Gear Shapers to our capabilities. Our capacities are constantly
EMAIL: [email protected] expanding, so please forward your specific requirements
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WEBSITE: WWW.ABUNDANTMFG.COM Technical Support: Via Telephone. Fax or E-mail
Training: Operator, Set Up & Maintenance SPIRAL BEVEL
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Preventive Maintenance plans: Customized to 32 DP to 2 DP
.5 Module to 12 Module
Your Needs
Parts: New and/or Used STRAIGHT BEVEL
Retrofits – Counters, Servo Controllers, or Single .25” to 36” Diameter
and Multiple Axis CNC 32 DP to 1.5 DP
Hydrostatic Guides: Repair Service or Purchase New .5 Module to 16 Module

I am the former Service and Technical Support Manager Manufacturing ALL TYPES of custom gears:
for Fellows. Working with me are several former Fellows Spiral Bevels, Straight Bevels, Spurs, Helicals,
Service Engineers. Between us we have the knowledge Worm and Worm Gears, Herringbones, Racks,
and capability to support all modes of Fellows shapers Splines, Internal Gears, Sprockets, Ratchets
from the oldest to the newest CNC and Hydrostroke Tooth Cutting, Grinding & Shaving services available.
GEAR GRINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27” DIAMETER machines. Please consider us for all of your Shaper needs.
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GEAR SHAVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24” DIAMETER Telephone: 802-259-2937 708-652-1100

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ABUNDANT — GEARED TO SERVICE YOUR NEEDS! CIRCLE GEAR and MACHINE
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48 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

 KA-WOOD GEAR & MACHINE
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797 EAGLE DRIVE • BENSENVILLE, IL 60106 Visit our Website at www.kreiter-geartech.com
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gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 49

industryNEWS << from page 43

slow down the spindle performance and toolholder, with an HSK-A100 option. The match that torque, the spindle employs 50
adversely affect cycle times. The built-in spindle on the a81M has an available 744 hp from 2,000 to 5,000 rpm. This duty rat-
motor method used in the a81M also pro- foot pounds (1,009 Nm) peak torque rating. ing and continuous output of the Makino
vides an advantage against vibration as The a81M spindle has no corresponding spindle lends itself to difficult cutting.
compared with the gear-type. loss of acceleration and deceleration. The The Makino a81M has an X-, Y-, and Z-
The Makino high-torque integral drive quick acc/dec ranges are from 4.4 sec- axis of 35.4 x 31.5 x 40.1 inches (900 x
spindle employs a standard CAT 50-taper onds to 3.8 seconds at 8,000 rpm. To 800 x 1,020 mm). It has a rapid feed
rate and cutting feed rate of 1,420 IPM
(36 m/min) in X- and Z-axis and a 1,182
IPM (30 m/min) in Y-axis. It has a 25
inch pallet (630 mm) able to handle work-
T H E S E V E N T H L A R G E S T U S E D M AC H I N E RY WA R E H O U S E I N T H E W O R L D loads of up to 10, 800 pounds (4,900
Kg). The thrust capacity of the a81M has
25 percent more axes thrust than the
previous a81 machine. The center trough
hinged conveyor provides for fast and
effective chip evacuation, and it has a
40-tool ATC as standard.
No one will do more to lower machining
costs than Makino, a global provider of
advanced machining technology and appli-
Mohawk Machinery has been helping companies get
cation suppor t for the metalcutting and
MAXIMUM RETURNS on equipment
die/mold industries. Makino manufactur-
for more than 50 years. ing and ser vice centers are located in the
United States, Japan, Germany,
WE HAVE A VARIETY OF FLEXIBLE SERVICES
TO FIT YOUR NEEDS Singapore, Italy, France, Korea, Taiwan,
Turkey, China, Mexico, Brazil, and India,
CONSULTING and are they suppor ted by a worldwide
Customized marketing plans designed distributor network.
to meet your company’s unique
business needs. For more information call (800) 552-
APPRAISALS 150,000 SQUARE FOOT 3288, or visit Makino on the Web at
Take it to the bank: Accurate, USED MACHINERY WAREHOUSE
expert equipment appraisals [www.makino.com].
from AMEA-certified appraisers. •
AUCTIONS ALL AT ONE LOCATION
Over $44 million gross sales in the 2,500 MACHINES IN STOCK
last three years. •
LIQUIDATIONS TWO 50 TON P&H CRANES
The right buyers...the right prices.
•
BROKERAGE
A sensible, commission-based sales option.
RAILROAD SIDING
CORRECTION:
CONSIGNMENT
A full-service partner you can depend on. Winzeler Source for Precision
STORAGE Molded Plastic Gears
Secure storage at a reasonable price.
In the November 2005 “buyer’s guide”
issue of Gear Solutions magazine,
Winzeler Gear should have been listed as
a source for precision molded plastic
gears, including design, consulting, manu-
facturing, and testing. John Winzeler can
10601 Glendale Road • Cincinnati, Ohio 45215
Phone (513) 771-1952 • Fax (513) 771-5120 • Email: [email protected] be reached at (708) 867-7971 or jwinzeler
www.mohawkmachinery.com @winzelergear.com. The company’s Web
site is [www.winzelergear.com].

50 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

advertiserINDEX DixiTech CNC
a division of Dixie Machinery, Inc.
COMPANY NAME PAGE NO.
Abundant Manufacturing, Inc. . . . . . . . . . . . . . . . . . . . 48
Accucut Diamond Tool Co. . . . . . . . . . . . . . . . . . . . . . . 17
AGMA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Allen Adams Shaper Service . . . . . . . . . . . . . . . . . . . . 48
Allied Sinterings, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Arrow Gear Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
B & R Machine & Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bourn & Koch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Buypass Dealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Circle Gear & Machine . . . . . . . . . . . . . . . . . . . . . . . . . 48
CNC Machinery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cole Manufacturing Systems, Inc. . . . . . . . . . . . . . . . . 48
CST-Cincinnati . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Dixie Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,51 RETROFIT • REBUILD
eldec USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 REMANUFACTURE • SERVICE
Encoder Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Erasteel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IFC DixiTech CNC specializes in the retrofit, rebuild, remanufac-
ture and service of metal cutting machine tools. We have a
Fairfield Manufacturing Co., Inc. . . . . . . . . . . . . . . . . . IBC specialty with gear machinery, all makes all models, includ-
Gear Motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 ing Gleason, Liebherr, Pfauter, Klingelnberg, Fellows,
Hanik Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Reishauer, G & E and Barber Colman.We also have extensive
High Performance Gear . . . . . . . . . . . . . . . . . . . . . . . . . 2 experience with turning machines, machining centers and
grinders such as, Mazak, Mitsubishi, Cincinnati Milacron,
Index Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Heald, Makino, G & L and Okuma. Our production process
Innovative Rack & Gear . . . . . . . . . . . . . . . . . . . . . . . . 49 in our machine bays and ourmechanical/CNC aptitude
James Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 allows for seamless integration for machine rebuilding.
Ka-Wood Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Our engineering staff routinely handles multiple projects
KAPP Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 concurrently. We have years of experience working with
Kreiter-Geartech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 gear machinery and the precise tolerances required for
Midwest Gear Corporation . . . . . . . . . . . . . . . . . . . . . . 49 these machines to cut spiral bevel, straight bevel and
worm gears. These gears are for industries in aerospace,
Mitsubishi Gear Technology Center . . . . . . . . . . . . . . .BC
automotive, marine, and critical defense applications, where
Mohawk Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 tolerances have to be precise.
Myron Bowling Auctioneers . . . . . . . . . . . . . . . . . . . . . 47
When it comes to CNC/NC/PLC controls, we support
Nachi Machining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Siemens, GE Fanuc, Allen Bradley, Heidenhain and Square
National Bronze & Metals, Inc.. . . . . . . . . . . . . . . . . . . . 9 D platforms. We stay ahead of trends in technology and
New England Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 educate our engineers with OEM courses. We also have on
Nye Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 site technical support and emergency service.
Overton Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 DixiTech CNC works with our customers to find solutions
P&G Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 allowing their production to remain uninterrupted. We have
Quality Transmission Components . . . . . . . . . . . . . . . . 38 over 100 years experience and knowledge of gear machin-
ery and metal cutting machine tools.
R. P. Machine Enterprises, Inc. . . . . . . . . . . . . . . . . .3,15
Raycar Gear & Machine . . . . . . . . . . . . . . . . . . . . . . . . . 9
Repair Parts, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DixiTech CNC
Schwartz Precision Gear Co. . . . . . . . . . . . . . . . . . . . . 49
A division of Dixie Machinery, Inc.
Internationally Renowned Gear Specialists
Setco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Standard Steel Specialty . . . . . . . . . . . . . . . . . . . . . . . 49 1798 Fairgrove Ave., P.O. Box 837
Hamilton, OH 45012-0837
Stor-Loc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Phone: 513-869-2900 • Fax: 513-869-2905
TalkGEARS.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Email: [email protected]
TSA America LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 www.dixiemachineryinc.com
Willman Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

gearsolutionsonline.com • JANUARY 2006 • GEAR SOLUTIONS 51

Q &A Our Conversations
With Industry Leaders
jerryHENDRICKSON
Vice President of Sales, Willman Industries, Inc.

GS: Give us a little background infor- received the Meehanite MAC 2000
mation on the company. Quality Award for Excellence, in fact,
JH: Our president, Clay Willman, purchased which is quite an accomplishment in our
the company from Medallist, Inc., in industr y. As for gear manufacturers, we
1987. Prior to that it was called State work with quite a few, including Avon
Foundry, and it was owned by a man Gear, Brad Foote Gear, Milwaukee Gear,
named Ed State. But there’s been a and Morris Materials, and we make plan-
foundry on this site for nearly 100 years. etar y housings for companies like
We currently have 150,000 square feet of Caterpillar Tractor, Rexnord, Industrial
manufacturing space, and we employ Motion Controls, and Twin Disc.
approximately 150 people.
GS: Sounds like you’re quite diversified,
GS: How long have you been with the in terms of your capabilities and cus-
company, and what are your responsi- tomer base.
bilities? JH: That’s true, especially in terms of how
JH: I joined the company in 1978, so I’ve our business is distributed. As an exam-
been here for 27 years. As vice president ple, if we use 150 as the number of
of sales I oversee the efforts of our in- active customers we have, our top 10
house sales staff, which probably handles customers probably represent 50 percent
about 90 percent of our business, with the of our business, but no one customer has
remaining 10 percent generated by outside more than 20 percent of our business. So
sales representatives who are found in from that standpoint, yes, we’re well
strategic locations around the country. diversified across industr y segments and

GS: Who are your customers, and

across the larger customer base.
“WHILE THERE ARE ALWAYS
where are they found? GS: What would you say Willman
JH: We work with Caterpillar and the Trane Industries is best known for, in terms PRICE PRESSURES TO BE
Company, just to name a couple, and even of its reputation?
though most of our product is sold domesti- JH: I think we’re known for the quality of DEALT WITH, HAVING A
cally, it ultimately finds its way into equip- our products and the service we provide to
ment that’s in use all around the globe. The
markets we serve include everything from
our customers. While there are always price
pressures to be dealt with, having a reputa-
REPUTATION FOR QUALITY
agriculture to automotive, construction,
diesel, energy, machine tools, marine, min-
tion for quality and service strengthens our
case in competitive bidding situations. And
AND SERVICE STRENGTHENS
ing, oil and gas, paper and printing, power
transmission, the railroad industry—just a
the precision of the parts we manufacture
has helped bring in business when other
OUR CASE IN COMPETITIVE
very broad range of manufacturing and serv-
ice industries. And our envelope of capabili-
foundries have not been able to meet the
customer’s requirements. In fact, even BIDDING SITUATIONS.”
ties is also quite broad when it comes to though we’re a jobbing foundry and often
sizes, encompassing everything from a cast- work directly from the plans that our cus-
ing weight range from one pound to 30,000 tomers provide, we also have an engineer-
pounds. We make most grades of gray iron, ing department that can help develop cast-
ductile iron, austempered ductile iron, high- ing designs that lead to a nearer net-shape
silicon iron for high-temperature applications product. And not only does that result in a
such as exhaust manifolds, and we’re also better product, it can provide significant
a meehanite-licensed foundry. We’ve cost savings as well.

FOR MORE INFORMATION

To learn more about Willman Industries, Inc., which is based in Cedar Grove, Wisconsin, call (920) 668-8526. Send e-mail to jhendrickson
@willmanind.com, or go online to [www.willmanind.com].

52 GEAR SOLUTIONS • JANUARY 2006 • gearsolutionsonline.com

 Ready, Willing and Able...

capable, reliable, serviceable, affordable,

profitable... MITSUBISHI GEAR MACHINES
Gear Technology Center
Division of Mitsubishi International Corp.
46992 Liberty Drive • Wixom, Michigan 48393
248-669-6136 fax 248-669-0614
www.mitsubishigearcenter.com

For Return Information, Fax To:

205-380-1580