Investigations On The Efficiency of Worm Gear Drives: Company Profile

GEAR SOLUTIONS MAGAZINE
INVESTIGATIONS ON THE EFFICIENCY OF WORM GEAR DRIVES
Investigations on the
Efficiency of Worm Gear Drives
ISSUE FOCUS
Lubrication & Broaching
COMPANY PROFILE:
Syn-Tech Ltd.
MARCH 2016
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As a highly technical specialty lubricants formulator and manufacturer, Syn-Tech Ltd.

evaluates each application as a unique set of parameters for a correct lubricant match,
earning the respect of many longtime customers.
32
28
Investigations on the Efficiency

of Worm Gear Drives
By Eva-Maria Mautner, Werner Sigmund, Johann-Paul Stemplinger, and Karsten Stahl

Experimental investigations on different worm gears were conducted on several test rigs, taking into
consideration the influence of different gear ratios, worm wheel materials, lubricants, and contact
pattern on efficiency and load-carrying capacity. Recommendations for an increase in overall worm
gearbox efficiencies are presented.
46
Shear Stability Is Key to Proper EAL Gear Oil Selection
50
An Update on Broaching Technology
By Ben Bryant and Craig Desrochers
To prevent failures of bearings and gears, careful selection of EALs for use in marine components,
combined with a good oil sampling program, are necessary.
By Dwight Smith
Advances in both broach tools and broach machines have progressed the state of the art
in broaching.
MARCH 2016
PRECISION.
PERFORMANCE.
PERFECTION.
FIRST TIME.
EVERY TIME.
Manufacturers of:
Broaches
Spline Broaches
Fine Pitch Gear Broaches
Form Broaches
Serration Broaches
Bearing Cage Broaches
Shaper Cutters
Disk Shapers
Shank Shapers
Hex and Square Cutters
Special Form Cutters
Inspection
Master Gears
Go-No Go Gages
Posiloc Arbors
Quick Spline Software
and Universal Gear Company

1605 Industrial Drive
Auburn, CA 95603
Phone: (530) 885-1939
Fax: (530) 885-8157
Call 530-885-1939 or visit

www.broachmasters.com
DEPARTMENTS
INDUSTRY
08

NEWS

Reports, data, and developments to keep

you aware of whats happening with your
colleagues in the gear-manufacturing
industry around the country and world.
Gleason Announces Availability of

Global Services App for Mobile Devices
Smart Drive Brings Sustainable

Progress to Construction and
Agricultural Machinery
In this section, the premier supporter of gear manufacturing in the United States
and beyond shares news of the organizations activities, upcoming educational and
training opportunities, technical meetings and seminars, standards development,
and the actions of AGMA councils and committees.
MATERIALS
20

MATTER
Matt Bell
OPTIMIZING PERFORMANCE WITH SURFACE
FINISH AND LUBRICATION
Lubrication in mechanical power transfer systems can have
superfluous or detrimental properties if not optimized relative
to the surface finish of the components.
15
American
Gear Manufacturers
Association
PRODUCT
60 Q&A
53

SHOWCASE

Stephan Hecht
Oelheld GmbH
TOOTH
22

TIPS

Matt Mondek
VARIABLES FOR QUALITY DESIGN: APPLICATION
A complete understanding of where the gearing will be used,
the surrounding environment, and external influences is an
essential starting point for achieving a quality design.
TREND
24

TALKS
Anna Claire Howard
QUALITY CONTROL AND INSPECTION
When it comes to manufacturing high-quality gears, quality
control and inspection play crucial roles in meeting industry
standards and a customers specific needs.
HOT
26

SEAT
Edward Rolinski
MODERN NITRIDING TECHNIQUES FOR GEAR APPLICATIONS
Among thermochemical methods, the processes of plasma
nitriding and gas nitriding have progressed in the industry to
increase gear performance.
Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway,
Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year.
Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER:
Send address changes to Gear Solutions magazine, P.O. Box 1210, Pelham, AL 35124. Publications mail agreement
No. 41395015 return undeliverable Canadian addresses to P.O. Box 503 RPO West Beaver Creek, Richmond
Hill, ON L4B4R6. Copyright 2006 by Media Solutions, Inc. All rights reserved.
No part of this publication may be reproduced or transmitted in any form or by any means, electronic or
mechanical, including photocopy, recording, or any information storage-and-retrieval system without permission
in writing from the publisher. The views expressed by those not on the staff on Gear Solutions magazine, or who are
not specifically employed by Media Solutions, Inc., are purely their own. All Industry News material has either
been submitted by the subject company or pulled directly from their corporate web site, which is assumed to be
cleared for release. Comments and submissions are welcome, and can be submitted to editor@gearsolutions.com.
MARCH 2016
VOLUME14 / NO. 03
Cover Photo: iStock
MARCH 2016
EDITOR'S
LETTER
David C. Cooper
PUBLISHER
Chad Morrison
Welcome to this issue

of Gear Solutions magazine.
Its March and for most of you, you are starting to enjoy the warmer days of spring. For
us in Alabama, we had many summer-like days throughout this past winter, so I decided to
go north for my annual snowboarding trip. I admit it was hard to come back from the snowy
mountains, but I was excited to put together this March issue of Gear Solutions magazine for
you. Once again, our contributors have been truly amazing and inspiring.
This month, we focus on lubrication and broaching. We bring you a profile on Syn-Tech
Ltd., a company that has made its mark in the lubrication industry with its introduction
of zero migration lubricants, which received recognition from the Society of Automotive
Engineers (SAE) and was chosen by a prestigious panel in the automotive industry for the
SAE 2016 World Congress exhibition. We wish Syn-Tech a successful show!
For our feature articles this issue, first we selected a paper on the investigations of worm
gear drives. The presentation from Eva-Maria Mautner with the Gear Research Centre (FZG)
was well-received at AGMAs 2015 Fall Technical Meeting in Detroit for its experimental
and theoretical results of FZGs project regarding overall gearbox efficiency. The results
consider the influence of worm gear geometries, materials, lubricants, as well as lubrication
and operating conditions on efficiency.
Our next feature, a paper from Klber Lubrication, covers lubricants specifically used
in marine components that meet environmental requirements from the EPA and discusses
the importance of a complete performance analysis and shear stability factors and provides
results from testing a lubricants ability to maintain consistent viscosity.
Weve also covered the world of broaching with an article from Dwight Smith with Federal
Broach and Machine Company. Dwight addresses where the industry has been and how it
has evolved due to advancements in broach tools and broach machines.
This month, our Hot Seat columnist Edward Rolinski and Tooth Tips columnist Matt
Mondek return to share their expertise with you, and we welcome Matt Bell with REM
Surface Engineering who continues the Materials Matter series on surface finishing.
We wrap up the March issue with a Q&A with Stephan Hecht, executive vice president
of Oelheld, a leader in innovative fluid technology. Stephan provides interesting insights
into this ever-changing sector and a background on Oelheld, a company you may have met
at last years AGMA Gear Expo.
As always, it was a pleasure working with the admirable contributing feature authors, our
engaging monthly columnists, the company profile, and the Q&A this month. I want to
thank each of them for making this publication a worthy and rewarding reason to come
back from snowboarding on the mountain.
I hope you enjoy this issue of Gear Solutions magazine!
ASSOCIATE PUBLISHER
EDITORIAL
Molly J. Rogers
EDITOR
Anna Claire Howard

ASSOCIATE EDITOR
SALES
Chad Morrison
ASSOCIATE PUBLISHER
CIRCULATION
Teresa Cooper
MANAGER
Kassie Boggan
COORDINATOR
Jamie Willett
ASSISTANT
ART
Shane Bell
CREATIVE DIRECTOR
Michele Hall
GRAPHIC DESIGNER
CONTRIBUTING
WRITERS
MATT BELL
BEN BRYANT
CRAIG DESROCHERS
JILL JOHNSON
EVA-MARIA MAUTNER
MATT MONDEK
EDWARD ROLINSKI
WERNER SIGMUND
DWIGHT SMITH
KARSTEN STAHL
JOHANN-PAUL STEMPLINGER
Vertical Logo
Molly J. Rogers
Editor
Gear Solutions magazine
editor@gearsolutions.com
(800) 366-2185 x205
PUBLISHED BY MEDIA SOLUTIONS, INC.

P. O. BOX 1987 PELHAM, AL 35124
(800) 366-2185 (205) 380-1580 FAX
David C. Cooper
PRESIDENT
Chad Morrison
VICE PRESIDENT
Teresa Cooper
OPERATIONS
gearsolutions.com
Coop w
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INDUSTRY
NEWS
NEW PRODUCTS, TRENDS, SERVICES,

AND DEVELOPMENTS
Martin Sprocket & Gear Inc. Opens Pittsburgh Manufacturing Branch

Martin Sprocket & Gear, Inc., a leading manufacturer of power
transmission parts and material handling systems, expands its U.S.
service offering and inventory availability in the Northeast with
the recent opening of a new Pittsburgh manufacturing branch in
Zelienople, Pennsylvania.
As one of 30 Martin locations in North America, the Pennsylvania
facility will stock a deep inventory of more than 30,000 SKUs from
Martins power transmission, material handling, and conveyor pulley
product lines. The Pittsburgh location offers same-day shipping on
all stock and custom-altered parts. In addition, made-to-orders can
be completed in days.
Another advantage the Pennsylvania facility will offer to distributors and to industrial businesses in the Northeast is complete access
to Martins vast manufacturing resources throughout North America.
In over 60 years of serving the power transmission industry,
Martin has established a reputation for delivering quality products and reliable service, said Ed Wright, vice president of the
Northeast region for Martin Sprocket & Gear, Inc. The commitment to customers extends to Martins Pennsylvania branch, which
will offer value-added services such as after-hours and emergency
services, local customer service, local field support, and reverse
engineering capabilities.
FOR MORE INFORMATION: martinsprocket.com
Gear Motions Names New Vice President of Buffalo Operations

Gear Motions, a leading precision gear
manufacturer, has named Paul Andruszko
as vice president of its Buffalo, New York,
operations, which includes its Oliver/
Pro-Gear and Niagara Gear divisions.
Andruszko has more than three decades
of experience in the gear industry and most
Paul Andruszko
recently served as general manager of the
companys Niagara Gear division. He has replaced Michael Barron,
who retired in December after leading Oliver/Pro-Gear for more
than 20 years. Oliver/Pro-Gear creates custom gears for all types
of equipment, including elevators, ski lifts, petroleum exploration,
production, and refining equipment, in low to moderate volumes.
Niagara Gear manufactures precision ground spur, helical, and pump
gears for a large and diverse global customer base.
Gear Motions is committed to delivering products that meet
world-class specifications for quality, safety, and efficiency and
exceeding our customers expectations, Barron said. Im confident
our customers can expect [that] the same level of quality and attention
to detail will continue and flourish under Paul Andruszkos leadership. He has the talent, knowledge, and hands-on experience in gear
design to lead Oliver/Pro-Gear and Niagara Gear into the future.
Andruszko joined Gear Motions in 1988 as a manufacturing
engineer in the companys Niagara Gear division. He has since held
numerous positions within the company, including operations and
engineering manager. Prior to joining Gear Motions, he gained
engineering experience at Pratt and Whitney Aircraft, a division of
United Technologies that designs, manufactures, and services aircraft engines and auxiliary power units. He has a bachelors degree
in mechanical engineering from the University of Hartford in West
Hartford, Connecticut.
Mike Barron and I worked closely together so that the transition
of leadership is as smooth and seamless as possible, Andruszko said.
Our Buffalo divisions will continue to provide extraordinary service
to our existing customers while helping new clients design gears that
will make their operations smoother and more efficient.
FOR MORE INFORMATION: gearmotions.com
Gleason Announces Availability of Global Services App for Mobile Devices

Gleason Corporation unveiled its new Global Services app, providing its customers a direct interface to the Gleason
Global Services network from any location in the world. This innovative service may be downloaded for free via
the App Store (Apple iOS) or Google Play (Android). It is also available on the Gleason website.
This new service app allows customers to:
Quickly complete and submit service contact forms (including any photos) directly to Gleason field service personnel.
Easily access 24/7 service support contact information via push to dial/email functionality.
Companies wishing to submit materials for inclusion in Industry News should contact the editor, Molly J. Rogers,
at editor@gearsolutions.com. Releases accompanied by color images will be given first consideration.
gearsolutions.com
Browse the complete service product portfolio.

Obtain global sales and service contact information via push to
dial/email functionality.
Learn about the latest Gleason service news and special offers.
Access the Gleason website and the companys YouTube channel.
Gleason has the largest installed base of gear production equipment

in the world with machines in more than 60 countries, said John
Perrotti, president and chief executive officer. Our Global Services
app is an initial step towards developing mobile tools to increase the
velocity and effectiveness of our global technical support activities.
FOR MORE INFORMATION: gleason.com
NTB Collaborates with Siemens, Sandvik Coromant, Iscar, and Kennametal To Make GTC Data
Exchange Format Available to the Public
NTB Interstate University of Technology Buchs, an institute that
specializes in engineering informatics, recently announced a new
website, gtc-tools.com, which provides information to the public
on the Generic Tool Catalog (GTC) cutting tool data exchange
format. The GTC data exchange format was developed through
collaboration among machining hardware and software leaders
Siemens PLM Software, Sandvik Coromant, Iscar, and Kennametal.
The GTC data exchange format is available to all tool vendors and
application developers, enabling them to share cutting tool data
more easily and precisely. GTC enhances the leading data exchange
format, ISO 13399.
GTC enables a direct connection between the tool vendor and the
application without the need of an intermediary company. GTC format catalogs from Sandvik Coromant, Iscar, Kennametal, and other
companies are currently being deployed into production by leading
manufacturing companies.
Having access to complete, reliable, and comprehensive cutting

tool data has been a need for computer-aided manufacturing (CAM)
and product lifecycle management (PLM) software users for a very
long time. ISO 13399, established by the International Standards
Organization, created a common language for industrial product
data, but there was also a need for additions to that information,
such as tool classification, class drawings, and pictures. GTC makes
this additional information available for use by cutting tool vendors
and applications developers.
Siemens PLM Softwares Manufacturing Resource Library (MRL),
part of its Teamcenter software portfolio that provides classification
and data management for manufacturing engineering resources, can
import catalogs in the GTC format. This enables the use of tool
data and 3D models in the creation of tool assemblies that can be
seamlessly used in Siemens NX software for tool assembly documentation and in NX CAM for tool path creation and simulation.
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This new website makes information about

GTC easily available to the general public,
said Marcel Keinan, director of product management for Siemens PLM Software. We are
fully committed to GTC. It specifies a standard format suitable for application developers
and avoids the need to create interfaces for different cutting tool vendors and applications.
Sandvik Coromant is one of the founders of
ISO 13399 and provides catalogs in the GTC
format compliant with this standard. GTC
is also supported in Adveon, a tool library
application developed by Sandvik Coromant.
Adveon interfaces to several CAM systems.
The GTC standard is a vital step forward

for the communication needed in the current
and future digital manufacturing environment,
Industry 4.0, said Per Nilsson, senior manager
of Intelligent and Digital Machining at Sandvik
Coromant.
Kennametal believes that customers should
have access to tooling data in the software of
their choice. In order to access essential cutting
tool information within the design and manufacturing processes, Kennametal is providing
customers with product catalogs in the GTC
format. Kennametal relies on NOVO for its
tool advisor and management application that
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will support the creation of GTC catalogs that

can be imported into Siemens software.
At Kennametal we believe in the future of
digital manufacturing, said Fred Patterson,
vice president of product engineering and a
founding member of ISO 13399. Partnerships
with companies like Siemens are critical to the
success of improving the way work is getting
done. Moving ahead with the GTC helps
the manufacturing community by integrating Kennametals tooling information in the
end-to-end product development processes.
FOR MORE INFORMATION:
sandvik.coromant.com
Liebherr Group Generates

Record Sales in the 2015
Business Year
Provisional figures show total sales revenue of
9,248 million for the Liebherr Group in 2015.
That is the highest revenue that the company
has ever achieved in its history. Year-on-year,
it represents an increase of 425 million or
4.8 percent.
Last year, Liebherr generated growth both in
the construction machinery and mining section and in the section covering the maritime
cranes, aerospace and transportation systems,
machine tools and automation systems, domestic appliances, components, and hotels divisions. Revenue from the construction machinery and mining product area increased by
337 million or 6.4 percent to 5,631 million.
This section includes the earthmoving, mining, mobile cranes, tower cranes, and concrete
technology divisions. In divisions other than
construction machinery and mining, revenue
increased by 88 million or 2.5 percent to
3,617 million. With a total exceeding 9.2
billion, Liebherr generated the highest sales
revenue in the history of the company.
REVENUE DEVELOPMENT
BY REGION
Business developed quite differently in the
various sales regions. Sales declined in Eastern
Europe and on the African continent. But
increases were posted in the Middle East, the
Far East and Australia, and in America. In
Western Europe Liebherrs most important
sales region revenue was largely unchanged
from the previous year.
EMPLOYEES
The number of employees within the Liebherr
Group rose again last year. At the end of the
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year, approximately 42,000 employees were tics center for the worldwide supply of spare
working for Liebherr. That represents a year- parts for Liebherr earthmoving machines
on-year increase of 1,080.
near Kirchdorf an der Iller, Germany. The
logistics center began operations at the start
INVESTMENTS
of 2015. In addition, the company continInvestments in the production sites and the ued the expansion of the production faciliworldwide sales and service network are ties for aerospace equipment at Lindenberg,
extremely important for the company. Last Germany. Liebherr successfully concluded
year, substantial investments were made totaling the construction of a subsidiary factory for
746 million.
drive and control technology components
Key projects included the expansion of the in Biberach an der Riss, Germany. Also at
diesel and gas engine production facilities at Biberach an der Riss, the tower crane producBulle, Switzerland, which extends over several tion company based there invested in a new
years, and the construction of a new logis- powder-coating facility.
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At Deggendorf, Germany, construction

work began on a new production site. Microprecision components will be developed and
produced there from the end of 2016. At
Ettlingen, Germany, the Liebherr Group
expands its center for remanufacturing drive
and control components with the construction
of a new hall. At the port of Fenit, Ireland, the
Irish maritime cranes production company
began the construction of a new assembly hall.
The domestic appliances production company
at Radinovo, Bulgaria, expanded its production and logistics infrastructure.
Furthermore, Liebherr invested in its sales
and service companies all around the world.
Liebherr-Australia Pty. Ltd. concluded its
expansion project at Adelaide and opened a
subsidiary in Auckland, New Zealand. The
Canadian Liebherr subsidiary expanded its
facilities at Burlington and opened a center
for remanufacturing mining components at
Acheson. Liebherr also strengthened its sales
organization in Switzerland by expanding
the facilities at Daillens. New customer centers were opened in Durban, South Africa,
Kusbass, Russia, and in Bogot, Columbia.
OUTLOOK FOR 2016

For the current year, the International
Monetary Fund expects the global economy
to grow slightly more strongly than it did in
2015. The Liebherr Group expects a moderate growth in revenue. Increases are expected
in most product areas. The Liebherr Group
will be at the upcoming Bauma trade show,
the leading international trade fair for construction machines, in Munich, Germany,
April 11-17.
The final figures for 2015 will be announced
by the Liebherr Group with the publication
of the Annual Report in June 2016. The figures stated here are based on forecasts from
November 2015.
FOR MORE INFORMATION: liebherr.com
Exceptional Product Quality
Smart Drive Brings

Sustainable Progress to
Construction and Agricultural
Machinery
On-Time Delivery
McInnesRolledRings.com/ExpectMore
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gearsolutions.com
More than ever, intelligent and sustainable

drive solutions that help reduce fuel consumption and thereby ensure environmentally friendly and efficient operation are in
demand today in the field of construction
and agricultural machinery. For these special
challenges, flexibility is needed, particularly
in regard to transmissions. Therefore, the

specialists at Stiebel-Getriebebau located
in Waldbrl, near to Cologne individually tune the drives for mobile hydraulic
applications to act as a dynamic link between
the combustion engine and the hydraulic/
electrical system.
Currently, a power take-off transmission
for pumps that was specially developed at
Stiebel-Getriebebau is helping construction
and agricultural equipment become more
energy-efficient. With a maximum input
power of 520 kW, a power take-off output
of 200 kW on each axle, and a power take-off
ratio of 1:0.8 for the engine speed, it is part
RAVE
GEARS
& &MACHINING
RAVE
GEARS
MACHINING
of a modular engine-transmission unit that
RAVEGEARS
GEARS&&MACHINING
MACHINING
enables economical energy and fuel consump- RAVE
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RAVE GEARS & MACHINING
In normal operating mode, the diesel
engine and the transmission are in use.
These operate the hydraulic auxiliary equipment and a generator that charges the energy
AS9100 CERTIFIED
storage system. The braking energy is also
ISO
9001-2008
CERTIFIED
AS9100
CERTIFIED
AS9100
CERTIFIED
used sustainably, with the help of the power
AS9100
CERTIFIED
AS9100
CERTIFIED
ISO
9001-2008 CERTIFIED
ISO
9001-2008
CERTIFIED
shift pump output of the power take-off
AS9100
CERTIFIED
ISO
9001-2008
CERTIFIED
AS9100
CERTIFIED
AS9100
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ISO
9001-2008
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ISO
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ISO AS9100
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Rave
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generator as electrical energy to the energy
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equipment and returning the
energy
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said Paul Hermann Schumacher, managing
Baker
Hughes,
Penske
Racing.
Baker
Hughes, Penske
Racing.
director of Stiebel-Getriebebau
GmbH
&
Current
customers
include
Bell Helicopter, SpaceX, United Techno
Co. KG. The demand for environmenBaker
Penske Racing.
tally friendly electrical traction
drivesHughes,
has
increased noticeably in recent years. And the
proven flexibility of our compact, robust,
and precise transmissions
will also continue to play
Rave Gears and Machining
an ever-increasing role
425 Strempel St. Seguin, TX USA 78155
Rave
and| 855-728-4327
Machining | 830-421-3295
(855) Gears
RAV GEAR
in this field, whether
Rave
Gears and
425
Strempel
St. Machining
Seguin, TX USA 78155
www.RAVEGEARS.com
Rave
Gears
and
Machining
for tractors, harvesters,
Rave
Gears
and
Machining
425
Strempel
St.
Seguin,
TX USA 78155
sales@ravegears.com
(855)
RAV GEAR
| 855-728-4327
| 830-421-3295
Rave
Gears
and
Machining
425
Strempel
St.
Seguin,
TXUSA
USA
78155
loaders, excavators,
(855)
RAV
GEAR
|
855-728-4327
| 830-421-3295
425
Strempel
St.
Seguin,
TX
78155
www.RAVEGEARS.com
425
Strempel
St.
Seguin,
TX
USA
78155
Rave
Gears
and
Machining
(855)
RAV
GEAR
|
855-728-4327
|
830-421-3295
www.RAVEGEARS.com
sales@ravegears.com
(855)
RAV
GEAR
Rave
Gears
and| 855-728-4327
Machining | 830-421-3295
sales@ravegears.com
(855)
RAV GEAR
| 855-728-4327
| 830-421-3295
www.RAVEGEARS.com
425
Strempel
St.
Seguin,
TX
USA
78155
www.RAVEGEARS.com
425
Strempeland
St. Seguin,
TX USA 78155
Rave
Gears
Machining
sales@ravegears.com

RAVE
GEARS
&MACHINING
MACHINING
RAVE
GEARS &
www.RAVEGEARS.com
sales@ravegears.com
(855)
RAV
|| 855-728-4327
| 830-421-3295
RAVGEAR
GEAR
855-728-4327
| 830-421-3295
sales@ravegears.com
425(855)
Strempel
St. Seguin,
TX USA
78155
www.RAVEGEARS.com
www.RAVEGEARS.com
(855)
RAV
GEAR
|
855-728-4327
|
830-421-3295
sales@ravegears.com
sales@ravegears.com
www.RAVEGEARS.com
sales@ravegears.com
MARCH 2016
Rave Gears and Machining
13
or other construction and agricultural

machinery of reputable manufacturers.
At Stiebel-Getriebebau, the technical
details are already taken into consideration
during the selection of the material. For
example, the shaft seals of Stiebel power
take-off transmissions for pumps are made
of viton, while the toothed hub profiles are
made of chromium molybdenum steel. Oillubricated hollow profile shafts prevent wearing of the pump shafts. The SAE motor
connections provide thermal relief of the
torsional vibration dampers using precisely

matched air vents. The diversity in the transmission ratios also provides a high degree of
flexibility. In many cases, oil cooling can be
eliminated because Stiebel combines a special lubrication system with strongly ribbed
housings. This results in high efficiency. In
addition, there are many special options that
will also be implemented in future energyefficient transmission solutions.
Stiebel-Getriebebau will be at the upcoming
Bauma trade show in Munich on April 11-17.
FOR MORE INFORMATION: stiebel.de
BROACH CUTTING TOOLS

HOW BOUT
I RIP YOU A NEW
ONE MORON!
DONT TALK
TO ME ABOUT
TOLERANCES,
IVE HAD IT
WITH YOU!!!
HELLO COLONIAL GUYS YOU GOTTA

HELP ME OUT HERE,
IM IN A HECK OF
A JAM
I DONT CARE
WHAT YOUR SUPPLIER
PROBLEMS ARE, I WANT IT
AS PROMISED.PERIOD!
I HAVENT HAD
A FAMILY DINNER
IN WEEKS!
WOW!
ON TIME &
ON BUDGET.
Colonial gives you the

opportunity to relax
& enjoy your coffee ...
...AND THE
LOWEST COST
PER PIECE..
GUARANTEED!
COLONIAL DOESNT KNOW IT BUT

THEY SAVED MY MARRIAGE AND MY
CUSTOMER. WITH TODAYS TIGHT
MARGINS YOU SIMPLY CANT AFFORD
TO TAKES CHANCES WITH QUALITY.
Surface Finishing and Abrasives

App Helps Metalworking
Professionals Work Better
Walter Surface Technologies, the global
industry leader in surface treatment technologies, recently announced the launch of
the new Walter Abrasives Selector app available for all iOS and Android smartphones.
The free app is designed to help metalworking professionals select the optimum abrasive
solution for any possible application they
may encounter.
Were an innovation leader in our
industry, bringing to market cutting-edge
product design and engineering, said
Dan Pirro, vice president of marketing for
Walter Surface Technologies. Our new
abrasives selector app will help our customers work more efficiently by putting technical knowledge and practical know-how
right on a workers smartphone.
Walter Abrasives Selector app highlights
include:
The app was designed specifically for metalworking professionals to get the best results
in grinding, cutting, and finishing applications by using the optimal abrasive and
process based on specific job parameters.
The simple user interface makes the app
easy to use. Select the operation (finishing,
sanding, cutting, grinding, or blending),
specify the tool of choice, and select the
desired finish.
Access technical reference data easily,
including safety data sheets, training videos, and Walter product information. Save
and email configurations for future reference or for ordering.
The Walter Abrasives Selector app is
available on the App Store (Apple iOS 7.1
or later) or Google Play Store (Android 4.2
or later).
FOR MORE INFORMATION: walter.com
Start your day with confidence.

Have your coffee your way!
EXPERIENCED RELIABLE INTERNATIONAL
United States Canada Mexico

1-866-611-5119 info@colonialtool.com www.colonialtool.com
14
gearsolutions.com
American
Gear Manufacturers
Association
Jill Johnson
Director of Member
Services
AGMA
Special AGMA Events Throughout 2016

To Celebrate Our Centennial Year
By Jill Johnson
This year marks a century that AGMA has provided a venue for
gear manufacturers to gather and discuss the unique facets of
our industry. Each year in the last 100 years, AGMA member
companies have collaborated to strengthen our industry with
technical standards, specialized education, statistical reports,
industry presentations, and networking events. This collaboration
has allowed AGMA to grow from the founding 19 companies to
close to 500 members in 2016.
The founding members put their collective minds together to
tackle the problems of noise and vibration of streetcar gears. The
achievements of our members have made gears
silent mechanisms and the optimal choice for such
a wide variety of devices that touch us in every
aspect of our daily lives. As we look back at the
past century of technological advances, we move
forward with strength to support the inventions
and ideas of the next 100 years and beyond.
AGMA has celebrated prosperous times, supported its members
through two world wars and economic downturns, and continues
to promote ingenuity and the creative spirit within its membership.
If you are currently not an AGMA member, now is the time to join
us. If you are part of our current membership, we encourage you to
come celebrate with us this year. We have a wide variety of events,
education, special webinars, and so much more.
The most important of these events is the AGMA/ABMA Annual

Meeting held May 12-14 in Amelia Island, Florida. We will be celebrating
the 100th anniversary for both associations, so the event will be filled with
world-class speakers, unparalleled networking events, and a look back at
the history and people that built the associations into what they are today.
This summer, we will be hosting a special event in Chicago to get all
of our Midwestern members involved in the centennial. On June 22,
join AGMA at the Drake Hotel for an evening of networking and
celebration with colleagues from the area.
Finally, the centennial year will end where AGMA began a century ago. The Fall Technical Meeting will be held
October 2-4 in Pittsburgh near the site of the
first AGMA organizing meeting and the original
home of AGMAs headquarters.
Beyond the centennial events, there are other
ways to get involved with AGMA this year. In
April, the Spring Marketing & Forecasting Conference will be held
in Rosemont, Illinois, and it offers an opportunity to network with
other sales and marketing professionals from the gear industry. The
conference also gives you the latest in gear industry economic data,
so that you walk away with an understanding of how your business
and your customers will fare over the near term.
Also this spring, AGMA is hosting a variety of education events
both in person and online. For newer employees, check out the Basic
Training for Gear Manufacturing at Daley College
in Chicago. AGMA hosts this gear school where
students start by learning the fundamentals of gear
manufacturing in the classroom and move to the
lab where they are provided invaluable instruction
and for some, a chance to cut their first gear.
More advanced gear engineers will benefit
from the Gearbox System Design in May and the
always-popular Gear Failure Analysis seminar in
June. Both courses are taught by world-renowned
experts in gearing that give students the benefit of
their decades of experience in the industry.
This year is the year to become an AGMA member, or if youre already a member, to get more
involved. Our centennial year is something to be
proud of, not just as an association, but as an industry. We hope youll join the celebration.
MARCH 2016
15
Celebrating
Years
Presenters Discuss the Gear Market at the AGMA

Marketing & Forecasting Conference on April 14-15
Growth in automotive production, housing construction, and capital spending are positive indicators
for gearing in the near future. However, uncertain government policies, a slowing energy sector, and
weak markets in Europe and Asia should also be considered. The AGMA Marketing & Forecasting
Conference has a lineup of presenters to help make sense of these competing forces.
This years Marketing & Forecasting event schedule will follow a
new format. On Thursday afternoon, April 14, join us for a special
presentation at 3:00 p.m. followed by a networking reception and
dinner. Return the following morning, April 15, for the Gear Market
Report presentation from IHS Global Insight. The event will finish
with lunch at noon.
Thursdays special presentation, Three Keys to Sales Success,
will be given by Randy Disharoon, vice president of Global Strategic
Accounts for Rexnord. Designed for company sales directors and sales
management, this energetic session introduces the three keys to sales
success: foundations, strategies, and disciplines. Every attendee will
leave empowered to set a firm foundation for consistent sales growth,
implement the plant method of sales, and sustain the winning pace.
Disharoon has an extensive background in
both industrial distribution and manufacturing, making him uniquely qualified to address
the issues that both types of organizations face
in todays market environment. He holds a
B.S. in engineering and two masters degrees,
including an M.B.A. At 23, he was certified
as a nuclear engineer. Two years later, he was
leading training courses for officers in the Navy
Nuclear program. He was soon promoted to
Randy Disharoon, VP
manager, overseeing the development of new
of Global Strategic
courses for the Pentagon.
Accounts, Rexnord
Disharoon entered the private sector at age
27 and immediately made an impact as the director of operations
with a distribution company where his team increased overall profitability by 31 percent. From there, he moved into a technical sales
16
American
Gear Manufacturers
Association
gearsolutions.com
role with an industrial manufacturer where his first year yielded

27-percent growth. Recently, Disharoons team achieved 42-percent
growth. With 25 years of sales, marketing, and leadership experience,
Disharoons presentations are relevant and interactive. His refreshing
approach equips every attendee to make an immediate and lasting
impact on their business.
On Friday, April 15, the conference will continue with the Gear Market Report presentation, forecasting the gear industrys activity for
the near and long term. The presenter, Tom
Runiewicz, is a principal/senior economist with
IHS Global Insight. As a principal for industry practice at IHS Global Insight, Runiewicz
is responsible for projections about the U.S.
industrial economy, including special aspects
about output, prices, costs, wages, capacity levTom Runiewicz,
els, and profit margins. He authored sections in
Principal/Senior
Economist
IHS Global Insights U.S. Economic, Industry
IHS Global Insight
Analysis, and Cost Forecasting service publications. He gained expertise in the paper and lumber, construction, steel,
agricultural, and service sectors. Additional responsibilities include
product line forecasting and consulting for clients that include many of
the Fortune 500 and national trade associations. Runiewicz has over 20
years of experience in the economic forecasting and consulting industry.
For more information on the Gear Market Report, AGMAs
quarterly report of gear market data, or to register for the
conference, visit www.agma.org.
This year marks a century that AGMA has provided a venue for gear
manufacturers to gather and discuss the unique facets of our industry.
Staff Changes in AGMAs Education Department

The history of AGMA, Celebrating 100 Years of Gearing, will be published in the spring
of 2016 and has a section titled, AGMA Becomes a Force in Education. It could have
just as accurately been titled Jan Alfieri Led AGMAs Efforts To Be a Force in Education.
For the thousands of industry professionals who have participated in an AGMA advanced
engineering seminar, a webinar, online course, or the Basic Training for Gear Manufacturing
over the last six years, Alfieri is a familiar face. From her first days with AGMA, she has
been an energetic advocate for making gears more visible.
Alfieri has decided to retire at the end of February after a very successful time leading
AGMAs development in responding to the great industry need for more programs to educate
and train the industry workforce. She has worked with an excellent committee of members
dedicated to developing seminars and resources to help members better understand and
educate their workforces.
She has also strengthened AGMAs relationships with key instructors including Bob
Errichello and Ray Drago. She created the Advanced Gear Engineering Certificate for individuals who have successfully completed
Casandra Blassingame
five of the seven advanced engineering courses more than 100 hours
of classroom training.
Employers have a valuable resource
in the Skills Assessment Tool to evalJan Alfieri
uate the detailed skills each worker
has or needs to improve.
In the last few months, Alfieri was key in helping to identify and hire her
successor. Because of her work, AGMA is a much stronger, more professional,
and more capable organization. Fortunately, she has agreed to continue helping Casandra Blassingame in her transition, so you may see Alfieri at one of
the upcoming advanced seminars.
Blassingame joined AGMA in January to serve as the new director of
education. She has a strong background in higher education with emphasis
on community and technical colleges. Her skills and knowledge will benefit
members in their recruitment and training efforts. Additionally, Blassingame
has developed and taught courses and has hired instructors. Her experience
with academic and community partnerships as well as the committee structure that accompanies those relationships has prepared her well to work with
Blassingame may be reached by email to:
AGMAs Education Advisory Council and others in the maintenance of current
blassingame@agma.org.
courses and the development of new courses.
1001 N. Fairfax Street | Suite 500 | Alexandria VA 22314 | (703) 684-0211 | www.agma.org
MARCH 2016
17
CALENDAR OF EVENTS
Whether youre looking for technical education, networking opportunities, or a way for your voice to be heard
in the standards process, AGMA has something to offer you. If you would like more information on any of the
following events, visit www.agma.org or send an email to events@agma.org.
MARCH
Working Group 2 March 10-11, 2016 AGMA Headquarters, Alexandria, Virginia

Wind Turbine Gearing Committee Meeting March 22, 2016 WebEx
Gearbox CSI: Forensic Analysis of Gear & Bearing Failures March 22-24, 2016 Concordville, Pennsylvania
Helical Gear Rating Committee Meeting March 29, 2016 WebEx
Metallurgy & Materials Committee Meeting March 30, 2016 WebEx
APRIL
Basic Training for Gear Manufacturing April 4-8, 2016 Chicago, Illinois
Cutting Tools Committee Meeting April 5, 2016 WebEx
Helical Gear Rating Committee Meeting April 12, 2016 WebEx
Metallurgy & Materials Committee Meeting April 13-14, 2016 Chicago, Illinois
Marketing & Forecasting Conference April 14-15, 2016 Rosemont, Illinois
Flexible Couplings Committee Meeting April 26-27, 2016 WebEx
MAY
Events are open to AGMA members only. Not a member? Send an email to membership@agma.org.
Gearbox System Design: The Rest of the StoryEverything but the

Gears and Bearings May 3-5, 2016 Clearwater Beach, Florida
Wormgearing Committee Meeting May 5, 2016 WebEx
Cutting Tools Committee Meeting May 6, 2016 WebEx
Wind Turbine Committee Meeting May 10, 2016 WebEx
Lubrication Committee Meeting May 11, 2016 WebEx
AGMA/ABMA Annual Meeting May 12-14, 2016 Amelia Island, Florida
Flexible Couplings Committee Meeting May 17, 2016 WebEx
Mill Gearing Committee Meeting May 19, 2016 WebEx
STAFF
Dean Burrows: Chairman

President, Gear Motions Inc.
Kenneth J. Flowers: Machine Tool Builders, Inc.

William Gornicki: ALD-Holcroft Vacuum Technologies Co., Inc.
Jim Bregi: Treasurer
President, Doppler Gear Company
John Cross: Chairman, BMEC

ASI Technologies Inc.
Thomas Maiuri: Chairman, TDEC

The Gleason Works
Lou Ertel: Chairman Emeritus
Overton Chicago Gear Corporation
Joe Franklin, Jr.: President

Amir Aboutaleb: Vice President, Technical Division
Jenny Blackford: Vice President, Marketing
Jill Johnson: Director, Member Services
BOARD OF DIRECTORS
EXECUTIVE COMMITTEE
AGMA LEADERSHIP
John E. Grazia: GearTec Inc.

Steve Janke: Brelie Gear
Aarnout Kant: Siemens AG, Mechanical Drives - Winergy
David Long: Chalmers & Kubeck Inc.
Justin McCarthy: Scot Forge Company
Don Michael: Martin Sprocket & Gear
Andrea Scanavini: Somaschini North America
Brian Schultz: Great Lakes Industry, Inc.
George Thomas: Bison Gear & Engineering Corp.
Wendy Young: Forest City Gear
General requests: webmaster@agma.org | Membership questions: membership@agma.org | Gear Expo information: gearexpo@agma.org
Technical/Standards information: tech@agma.org | AGMA Foundation: foundation@agma.org
18
gearsolutions.com
MATERIALS
MATTER
MATT BELL
RESEARCH CHEMIST
REM SURFACE ENGINEERING
OPTIMIZING PERFORMANCE WITH SURFACE FINISH AND LUBRICATION

Lubrication in mechanical power transfer systems can have superfluous or detrimental
properties if not optimized relative to the surface finish of the components.
MATERIALS AND MANUFACTURING PROCESSES HAVE
evolved to generate lighter, stronger, and more robust components
to meet the demand for more efficient, highly loaded mechanical
systems. The importance of the surface of these components relative
to their operational performance was presented in the December
2015 Materials Matter column, Gear Surfaces and Operational
Performance. Additionally, the lubrication of gears and bearings
plays an important role in the performance of the overall system. The
lubricant must be properly matched to the surface finish in order to
achieve maximum efficiency and operational life while minimizing
or avoiding any detrimental effects that said lubricant may have.
When gearboxes and other power transfer systems are designed,
the design engineer designates the correct oil to use based on the
theoretical characteristics of the components and their operating
regimes. Proper lubrication performs many required functions
most notably, maintaining separation between components and
reducing friction during operation.
In a geared system, friction is both detrimental and unavoidable.
When gear teeth run in mesh, the resistance to motion is, of course,
friction. This friction is generated primarily by the roughness of the
gear surfaces and the viscosity of the lubricant. The energy necessary
to overcome this frictional force is wasted energy. Thus, one thing
we can do to improve the efficacy of any power transfer system is to
minimize energy losses due to friction.
The Stribeck Curve in Figure 1 suggests that there is an optimal
choice of lubricant for a given application that will result in the
lowest coefficient of friction. A lubricant must have adequate viscosity or thickness to maintain separation of the components and
therefore reduce wear. However, as viscosity increases, the efficiency
of the system in relation to the lubricant decreases due to the inher-
Figure 1: Stribeck Curve
20
gearsolutions.com
ently higher fluid friction. Thus, the optimal lubricant will have the
minimum required viscosity to maintain separation between the
interacting surfaces.
If we consider the first law of thermodynamics, i.e., energy within
a system can neither be created nor destroyed, only converted, then
we must accept that the parasitic frictional losses within a geared
system dont just disappear. Rather, this energy is being converted to
other wasteful forms such as heat and noise. The conversion to heat
is doubly problematic as the wasted energy now alters the viscosity
of the oil (reducing it), which in turn can lead to increased friction
and wear due to the physical interaction or rubbing of the gear
teeth. Thus, the specified lubricant must have an adequate viscosity
to maintain separation at the predicted operating temperatures. As
wear in the system increases debris in the lubricant and this debris
serves to clog filters, exacerbate wear in gears, bearings, or both,
lubricants tend to be specified conservatively. Derivatively, the
energy loses due to the higher viscosity lubricants fluid friction are
commonly accepted as a necessary compromise.
To combat some of these tradeoffs relative to gear wear and frictional losses, lubricants make use of specialty additives. Lubricant
companies make a great effort in tailoring their additive packages
to improve the operational performance of the gear system. There
are many components that can go into the base oil as additives,
including anti-wear, extreme pressure, and antifoaming agents;
viscosity and lubricity modifiers; dispersants; and rust inhibitors.
While all of these additives have a function, they can also have
negative effects, either directly or derivatively. Additives add cost
and complexity to a system. As they are consumed or degrade, their
effectiveness decreases, thus reintroducing the risks that they were
meant to mitigate. Ultimately, many of these additives and the use
of thick lubricants are countermeasures that are being applied to
overcome non-optimal surface finishes. In other words, additives
and higher viscosity lubricants are not addressing the root cause of
the gear systems issues.
As discussed in the December 2015 column, the surface texture
of a ground or machined component affects performance. To
briefly summarize, cutting tools create machining patterns. A
simple way of illustrating these patterns is with a series of parallel,
alternating peaks and valleys (which could be classified as periodic
or anisotropic), much like the plowed field shown in Figure 2. This
surface texture is particularly unideal for gears during operation as
each peak is positioned such that it can most easily snag on a peak
from the mating gear. Thus, it is this interaction of the machining
patterns on meshing gear flanks that dictates the need for higher
viscosity lubricants.
Advanced surface finishing techniques aimed at reducing surface
roughness have become much more common in the last few decades.
Processes such as isotropic superfinishing can generate a very low
surface roughness on complex geometries through a planarization
mechanism. This process is discussed in the

October column, Isotropic Superfinishing,
and works by selectively removing the aforementioned peaks, forming larger and larger
flat areas until all peak asperities have been
removed and an isotropic surface has been
generated.
By eliminating the plowed field texture,
no peaks remain on the surface to penetrate
a lubricant film. This change to the surface
reduces parasitic friction created by any peak
asperity interaction and all of the problems
this friction creates (most notably, wear and
heat). By improving the surface finish and
texture of a component, the lubricant viscosity can now be significantly reduced. By
reducing viscosity, the system will benefit
from additional increases to efficiency as well
as a reduction in trapped air bubbles in the
lubricant itself (as lower viscosity lubricants
tend to suffer less from this phenomenon).
Further, provided that both mating gears have
been isotropically superfinished, it can be
expected that no peak asperities shall remain
to break through the lubricant barrier. This

change in operating performance will reduce
wear in the overall system and will therefore increase lubricant life. Lastly, the need
for complex and costly additive packages
is greatly reduced, if not eliminated, as the
underlying issue of non-optimal surface texture/finish has been addressed.
CONCLUSION
Lubrication has historically been the chosen
solution to wear and efficiency problems in
power transfer systems such as gears and bearings probably because it was thought to
be the only solution. While lubricants do represent a solution to these issues, they are not
the only solution, and in many cases, they are
not the optimal solution. As low roughness,
isotropically superfinished gears continue to
increase in prevalence, it seems likely that
the more synergistic solution of addressing
the surface roughness before optimizing the
lubricant will become the more common path
to optimizing gear systems.
Figure 2: The rows of a plowed field have a similar

appearance to the microscopic grind lines of ground/
machined gears
ABOUT THE AUTHOR: Matt Bell has been a research chemist with REM Surface Engineering since 2006 where he has developed new products
and processes, published several papers, and aided in corporate lean efforts. He is an expert in surface roughness measurements, a member of the
American Chemical Society, and serves on the AGMA 925 committee. He graduated from Texas A&M University with a degree in chemistry where he
also served as the vice president of the American Chemical Society student affiliate chapter. He can be reached at mbell@remchem.com.
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MARCH 2016
21
TOOTH
TIPS
MATT MONDEK
PRESIDENT
MONDEK SOLUTIONS
VARIABLES FOR QUALITY DESIGN: APPLICATION

A complete understanding of where the gearing will be used, the surrounding environment,
and external influences is an essential starting point for achieving a quality design.
IN THE FEBRUARY TOOTH TIPS COLUMN,
an overview was presented of the four major
elements application, specifications,
design, and process that dictate the
ultimate accuracy of gearing and how well
it satisfies the customer. Within this series,
we take a closer look at each, starting with
application.
APPLICATION
During the application phase, there is no need
to sharpen the pencil or fire up the computer
just yet. It is time to rely on common sense
and engage your teams accumulated years of
street smarts. Apply a basic methodology,
such as the flow diagram shown in Figure 1,
and ask many seemingly simple questions.
The more questions asked, the greater your
understanding will be of what has to happen
and what may influence the outcome.
The designers comprehension of these factors will be essential in establishing a solid
footing to guide the gear design and ultimately satisfy the customers requirements.
INPUT
The first question to ask is, what will be driving the gearing? Typically, the horsepower
and speed are provided, but these alone do
not tell the entire story. It is essential to look
deeper to fully understand the application
and expose additional details.
What will the input power source be? Will
the input power be from more than one
unit? Will it be diesel, gas, turbine, inline, V
8/10/12, or an electric motor?
Figure 1
22
gearsolutions.com
The sample output curves shown in Figures

2 and 3 illustrate some of the differences to
be aware of.
Additional questions you should ask
include: How will multiple inputs be governed? How much will the power fluctuate?
What are the speeds at which the unit will
be operating within, and if at a set rpm, what
are the torque pulses? Will the rpm vary? Will
the power be directly coupled, belt-driven,
or clutched? Will the engagement be quick
or gradual and at what speeds, and will it be
manually or electronically controlled? What
happens in the event of an abrupt shutdown,
loss of fuel, or a mechanical failure?
Engagement types can directly affect the
presence and magnitude of shock loading during start-up or transitional events. Secure the
actual horsepower curves for the power sources
and performance specifications for any coupler
or clutching devices. One other consideration
(not related to performance) is whether there
are any footprint or envelope restrictions.
OUTPUT
Once you have a firm understanding of the
input side, it is then necessary to scrutinize
the output. In most cases, the customer will
specify the basic requirements such as output
speed, the load to be driven, output orientation to input axis, and the typical duty cycle.
The relationship of the output to input speeds
and whether multiple speeds or change in
direction are necessary has to be defined. If
multiple speeds are required, consideration of
shifting mechanisms, multiple gear meshes,
Figure 2
Figure 3
and gearing configurations may be required.

The coupler questions previously raised are
repeated here for the same reason, but with
a focus on the driven member. The shock
loading to the driven member and the rate
at which the load is applied to the gearing
should be appreciated. Noise of the gearing
along with whether the driven load will vary
over time from first predicted is also a concern. Be mindful of the output placement and
if it satisfies packaging constraints.
EXTERNAL INFLUENCERS
This area is often overlooked yet it is frequently the cause of many failures. Be persistent in
asking questions, and look for the unusual.
Consider the environment bilaterally. What
might the incoming influencers be, and how
might the design impact the environment?
Incoming: Check out the practices and
habits of the customer. How will the gearing
be handled, cleaned, assembled, lubricated,
and maintained? If assembly is required,
is the design asymmetric to ensure proper
assembly? Anticipate misuse and compensate
for it in the design.
How will the gearing be supported or mounted? Will the gearing

or gearbox be subjected to long-term storage, and if so, how will it
be preserved and brought back online? Will the gearing be exposed
to any corrosive chemicals, excessive heat, cold, gases, or foreign
liquids? Can the gear enclosure breathe to the outside and entrap
moisture or create condensation? If so, how will the design accommodate it? A simple practice, such as pressure-washing a product,
while meant to keep it clean, can almost certainly drive cleaning
fluids and water past seals and into the assembly.
What will the immediate surroundings be, and can you isolate
the gearing from adverse conditions? Considerations for vibrations,
isolation mounting, protective surroundings, filtration, and a robust
maintenance schedule can be invaluable.
Outgoing: A holistic design also takes into consideration how
it may impact the environment. (See Figure 4.) Is the gearing
designed to minimize noise, will any oil vapors be released, is
the design safe for operation, and if a failure should occur, has
risk mitigation been considered? Is there an opportunity to use
less materials, increase recyclable content, and use materials with
lower environmental impact? Are manufacturing processes considered for energy efficiency, and can the gearing be reconditioned
and reused? Dont forget to consider end-of-use options as well.
These considerations can be even more relevant when working
with plastics.
Figure 4
CONCLUSION
A comprehensive and balanced understanding of the application and
how it interfaces with the environment is essential in developing a
solid design. The key, as stated before, is awareness to help guide
your design decisions.
ABOUT THE AUTHOR: Matt Mondek is the president of Mondek Solutions, a consulting business committed to driving the success of manufacturers
through common-sense implementation of multi-disciplined best practices and problem resolution. He has over 38 years of experience in P&L,
executive-level leadership, operational effectiveness, quality, and product design. For more information, contact Mondek at 815-382-1987, email
mmondek@mondeksolutions.com, or visit www.mondeksolutions.com.
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AEROSPACE
MARCH 2016
23
TREND
TALKS
ANNA CLAIRE HOWARD

ASSOCIATE EDITOR
GEAR SOLUTIONS MAGAZINE
QUALITY CONTROL AND INSPECTION

When it comes to manufacturing high-quality gears, quality control and inspection
play crucial roles in meeting industry standards and a customers specific needs.
GEAR QUALITY CONTROL AND INSPECTION ARE IMPORTANT
steps in the process of checking the overall quality of manufactured
gears and parts. It also provides insight into the levels of efficiency
and control as they pertain to the manufacturing process, ensuring
that the parts are made to meet high-quality standards as well as the
customers specific needs. It begins on the shop floor with everyday
tasks and extends its reach to the manufacturing lab for complex
analytical evaluations of the gear. All of these steps are necessary
to consistently maintain control of the manufacturing process and
keep the following factors in check: gear size, gear quality, fixture
mounting on the machine, machine setup, part blank quality, cutting
tool accuracy, mounting of the cutting tool, cutting tool sharpening,
and heat treating.
To address the industrys measurement and inspection needs,
companies have created technology to reduce the cost of specialized and dedicated devices,
such as Hexagon Manufacturing
Intelligences PC-DMIS Gear
metrology software.
According to Christopher
Fleshood, applications engineer supervisor for Hexagon
Manufacturing Intelligence,
the inspection of gears can be
a time-consuming project, and
factors such as table setup, correct tools, and proper training
can cause the process to be inaccurate and slow. PC-DMIS Gear 2.5
helps eliminate all these problems by having a simple fill-in-the-blank
interface that allows anyone with basic CMM knowledge to generate
an inspection routine for a gear.
This reduces the time to check a gear from hours to minutes,
Fleshood said. PC-DMIS Gear can check complex geometry on
a spiral bevel gear with ease. Now, instead of buying an expensive
dedicated gear-checking machine, you are able to use the tools you
already have to generate concise, accurate reports with a few clicks of
the mouse. Also, PC-DMIS Gear does not require an expensive rotary
table for measuring spur and bevel gears and supports inspection of
small spur gears with optical measurement devices.
Smaller companies such as Washington states Geartrology are
doing their part to meet gear manufacturers needs in these areas, too.
The company was founded in January 2014 by Gerry Rouillard who
first learned the art of gear grinding at the age of 14 on a Reishauer
gear grinder at his fathers gear manufacturing company. Four years
later, he worked his way up to the quality control department and
then onto process engineering and sales. Rouillard later founded his
own aerospace gear manufacturing company, International Gear
Technologies (IGT), and following in his fathers footsteps, made a
name for himself in the industry.
I owe my success to my father who gifted me the knowledge and
ingenuity that has inspired me to pursue advances in manufacturing technology and to create based on an actual need or shortcoming in the manufacturing process to improve speed and accuracy,
Rouillard said.
Geartrology offers complete rebuilding and retrofitting of instruments including Fellows 12M involute testers, Fellows 12H lead
testers, Fellows No. 8 Microdex, and all varieties of double flank
gear testers. Additionally, the company sells master gears and spline
gages and can present, propose, and create software for gear design
and manufacturing engineering,
as well as offer calibration services for all the above-mentioned
instruments.
Some of the challenges the
industry faces with quality control and inspection include a push
to move toward more automated
solutions for checking gears and
an increasing demand for more
informative reports that are easier
to interpret with more graphical
representations and a heavier use
of CAD for mapping data points.
Our customers express a strong desire to recognize salvageable
gear parts to help manage scrap through re-workable production
processes, which is especially important on low-volume projects,
Fleshood said. And the need for newer, faster, more accurate data collection technologies, such as laser and vision, is always a top priority.
For example, while vision systems have limited support now for gear
inspection, the need for non-contact data acquisition will continue
to drive software development and hardware support.
Additionally, the challenges typically boil down to cost. More and
more gear manufacturers require these automated solutions, yet some
on the market can be costly. According to Fleshood, PC-DMIS Gear
is an ideal entry-level package that can effectively check a variety of
gear types without the enormous price tag for a dedicated system.
Gear manufacturers must uphold a high standard of quality and
inspection to address the growing needs of the industry, and meeting
those needs will lead to an increased level of customer satisfaction
as their unique requirements are met, keeping the industry moving
in the right direction.
To address the industrys

measurement and inspection
needs, companies have created
technology to reduce the
cost of specialized and
dedicated devices.
ABOUT THE AUTHOR: Contact Anna Claire Howard, the associate editor of Gear Solutions, at 800-366-2185 ext. 204.
24
gearsolutions.com
Never settle for close when you can have precision fit.
When it comes to the mechanical components you count on, close just doesnt cut it. Common sense says a
poor fit and premature wear will eventually lead to failure. And no one has time for that. At Schafer, we specialize
in custom, precision-fit products designed to keep equipment moving. Simply put, our service, quality and on-time
delivery are second to none. Reliability is our trademark and it has helped us grow from Schafer Gear to Schafer
Industries. These days, our expertise doesnt end with gears. Now were leading the way in driveline, axle and brake
applications as well. So whether youre in the automotive, truck, marine, off-road leisure, heavy equipment
or aviation industry, look no further than Schafer. For more information visit us online.
SchaferIndustries.com
MARCH 2016
25
HOT
SEAT
EDWARD ROLINSKI
SENIOR SCIENTIST
ADVANCED HEAT TREAT CORP.
MODERN NITRIDING TECHNIQUES FOR GEAR APPLICATIONS

Among thermochemical methods, the processes of plasma nitriding and gas nitriding
have progressed in the industry to increase gear performance.
Figure 1: Worm gear during plasma nitriding (photo courtesy of Advanced Heat Treat Corp., Monroe, Michigan)
IMPROVING SURFACE PROPERTIES OF GEARS CAN BE

extremely beneficial since many failures start at the surface in the
contact area between the teeth [1]. Rolling contact fatigue properties
of the gear surface are improved when a hard diffusion layer with
the compressive residual stresses built into it by the thermochemical
surface engineering methods are applied. Such a layer prevents
or delays the formation of premature surface and subsurface cracks,
core crashing, or subsurface fatigue.
Well-known methods of the thermochemical treatments applied for
gears include carburizing, carbonitriding, ferritic nitrocarburizing,
and nitriding [2]. Although carburizing produces the thickest layer, it
is carried out at a high temperature, therefore, it must be followed by
quenching and tempering operations. That may cause some unwanted
distortion and a need for more aggressive final machining. Nitriding
is typically performed at a temperature of 390-570C, depending
on the type of steel and the case depth requirements, therefore, it is
considered as a distortion-free process. Nitriding of titanium gears
is carried out at above 690C (1,274F).
A significant increase in a gears performance can be realized by using
modern nitriding techniques. The process of nitriding is one of the most
promising of the verity of many thermochemical methods known to the
gear industry. For a long time, gas nitriding was used for gear applications
in combination with a final grinding operation. This machining process
was necessary because the layer that was formed during gas nitriding
had a brittle and hard layer at the surface, called a white layer, which
was built of iron nitrides that were frequently too thick and porous. It
26
gearsolutions.com
was not until the late 1960s to 1970s when the process of ion nitriding
(or plasma nitriding) was introduced and found full acceptance as a
panacea for the aforementioned problems of the gas nitriding process.
Ion nitriding is carried out in a vacuum with a very low partial
pressure of nitrogen reaching no more than 5 mbar. The process is
carried out in the DC-pulse glow discharge/plasma and can be seen
through the port window (see Figure 1), and its characterized by the
sputtering effect of the surface atoms by high-energy ions of nitrogen.
Both low partial pressure of nitrogen as well as the sputtering result
in the formation of a very dense white layer and with an absolutely
controllable thickness at the surface of the gear [3]. In many situations,
no final machining is required since post-nitriding surface roughness
changes are minimal, and the dimensional changes are almost nonexisting because the process is carried out at a temperature well below
the transition of ferrite to austenite. Also, the process of ion/plasma
nitriding is beneficial in many applications as it offers a simple, local
masking or protecting from hardening if required. Typical case depth
produced either by plasma or gas nitriding is in the range of 0.3-0.6
mm, although a much deeper case reaching 1 mm (0.04 inch) in thickness can be produced in a typical 3-percent Cr steel used for gears [4].
Plasma-nitrided gears made of titanium alloys achieve a uniform
gold-color characteristic of titanium nitride, TiN, formed at the surface
(see Figure 2). The nitride is not a coating like one used for cutting
tools, but rather a diffusion-type layer supported by Ti2N, Ti2 AlN,
and other nitrides and a much deeper diffusion layer of a-titanium
enriched with nitrogen. The layer has excellent tribological properties.
The progress achieved in the industry since the introduction of plasma nitriding has stimulated more research and development in the gas nitriding field,
resulting in the implementation of superior process control methods and reliable
atmosphere measuring devices such as hydrogen and oxygen probes [1]. This
has also afforded the development of a nitriding potential-controlled process,
which offers control of the white layer structure and its thickness and provides
the ability to treat the entire gear or gear component uniformly [1]. However, in
the plasma nitriding process, masking or local protection from the treatment is
comparatively simpler than in the gas nitriding process, which requires galvanic
copper plating.
REFERENCES
1. I. Bojadijev, J. Witzig, T. Tobie, and K. Stahl, Tooth Flank Fracture Basic
Principles and Calculation Model for Sub-Surface Initiated Fatigue Failure
Mode of Case Hardened Gears, Gear Technology, August 2015, pp. 59-64.
2. ASM Handbook Vol. 4A, Steel Heat Treating, Fundamentals and Processes,
Ed. ASM International and Heat Treating Society, 2013, pp. 1-768.
3. E. Rolinski, G. Sharp, When and Why Ion Nitriding/Nitrocarburizing
Makes Good Sense, Industrial Heating, Aug. 2005, pp. 67-72.
4. E. Rolinski, F. LeClaire, D. Clubine, G. Sharp, D. Boyer, and R. Notman,
Kinetic of Plasma Nitriding and Renitriding of 3% Cr-Mo-V Steel, Journal
of Materials Engineering and Performance, 9(4) (2000), pp. 457-462.
Figure 2: Titanium a+b alloy gear for aerospace engine after plasma
nitriding (photo courtesy of Advanced Heat Treat Corp., Waterloo, Iowa)
ABOUT THE AUTHOR: Dr. Edward Rolinskireceived his M.S. in manufacturing

technology in Warsaw, Poland, and received his doctorate for his research on
phenomenon in the ion nitriding process. He has taught physical metallurgy
and surface engineering and received his ScD (habilitation) for studying plasma
nitriding of titanium. Rolinski is a senior scientist at Advanced Heat Treat Corp. in
Monroe, Michigan, solving technical problems and developing technologies. For more
information, contact him at doctorglow@ion-nitriding.com or visit www.ahtweb.com.
MARCH 2016
27
COMPANY
PROFILE
Syn-Tech Ltd.
As a highly technical specialty lubricants formulator and

manufacturer, Syn-Tech Ltd. evaluates each application as
a unique set of parameters for a correct lubricant match,
earning the respect of many longtime customers.
By Molly J. Rogers
SYN-TECH LTD. IS A PRIVATELY HELD COMPANY
founded in 1968 by Reginald S. Reggie Shearer. Cutting
his teeth early on as a chemistry and physics major in
college, Shearer was an innovator from the start, focusing
on extreme environments and difficult applications. As a
young chemist, he sold some of the first synthetic oils in
the United States in the cold, harsh conditions of northern
Alaska to airplane pilots due to extreme low-temp engine
turnover problems.
Dedicated to pushing design limits and creating innovative lubricant formulas to solve problems for design
engineers, Shearer also formulated and manufactured
extreme aircraft lubricants for gearboxes in helicopters
and other aerospace applications that are still on the
cutting edge of lubrication abilities.
Today, Syn-Tech Ltd. continues to be committed to
innovation and problem-solving by second- and thirdgeneration Shearers. Headquartered in Addison, Illinois,
Syn-Tech is ISO 9001:2008 registered and has facilities
that include administrative offices, R&D, manufacturing, quality testing, and packaging.
Research and creative thinking are at the core of all
Syn-Tech Ltd. sales engineers and R&D chemists and
technicians. Syn-Tech Ltd. approaches each customers
application with the need to understand all parameters.
Although the company has over 3,000 lubricant formulations and may have an existing formulation as a viable
lubricant solution, the process stays the same research
the application thoroughly and then either formulate a
Quality manager, Jackie Shearer Feeley (far left); R&D manager,Skip

Shearer (back center); marketing director, Cindy Shearer Galloway (sitting
in front); and internal financial director, Pam Shearer (sitting on right)
new product or provide an existing lubricant formulation.

Our hands-on approach with the design engineer to
formulate and develop a lubricant that meets or exceeds
the requirements for the application creates lasting relationships with our customers, said Skip Shearer, R&D
manager at Syn-Tech Ltd. Generally, through the process
of working closely with our customers, we succeed with
a lubricant match the first time. In some instances, we
can create a prototype of the customers apparatus and
run parallel testing in our state-of-the-art research and
development laboratory.
Syn-Tech Ltd. recently completed a new research and
development laboratory to keep the company at the forefront of lubricant formulation. Its testing ability allows
new technologies and techniques to be created for the
benefit of its customers. The result is a large family of
lubricants that meets customer needs without using a
one-product-meets-all approach.
While Syn-Tech Ltd.s primary focus is the automotive
industry, the company also specializes in lubricants for
the aerospace, defense, industrial, medical, and commercial industries. In addition to formulating for individual applications, Syn-Tech Ltd. manufactures lines of
lubricants with varying viscosities, thickeners, and base
fluids including H-1 and H-2 food grade lubricants.
Every lubricant is developed in the companys research
laboratory.
Syn-Tech Ltd.s products are based on a full range
of synthetic chemistries including PAO, ester, glycol,
silicone, PFPE, and ionic liquid-based products, among
others. The company works closely with top lubricant
component manufacturers for design and field trials. In
addition, Syn-Tech Ltd.s mechanical and electrical engiMARCH 2016
29
neers work closely with product formulators to ensure that products

are being developed properly the first time to reduce testing burden
at the OEM. Its engineers have the ability to design test stands inhouse to run parallel testing with the customer. And as a service to
its customers, Syn-Tech Ltd. runs plastics and elastomer compatibility
screening at no charge.
For gear applications, Syn-Tech Ltd. offers lubricants that can dramatically increase the performance of a mechanism by providing longer
lasting, quieter operation over a wider operating temperature range.
Our formulations could possibly eliminate the need for special
seals and provide the design engineer with the option to use less
expensive gear materials or manufacturing processes, which can lead
to significant cost savings, said Shearer. Longer lubricant life due to
increased oxidation resistance will reduce downtime for maintenance,
leading to overall cost savings.
From steel mill gear reducers, critical helicopter transmission
gears to miniature geared actuators, Syn-Tech Ltd.s lubricants serve
to reduce wear and noise while increasing gear train efficiency.
According to Marketing Director Cindy Shearer Galloway, Syn-Tech
Ltd. has the knowledge and experience to formulate lubricants for
the harshest, most demanding gear applications.
For example, its NS-3913-G was developed specifically for gear
couplings for high PV applications formulated for both high loads
and at high speeds, as well as low speed and low loads. This synthetic
grease can be used for all coupling applications. It has a very high
viscosity index, exhibiting high film strength, good metal wetting,
low coefficient of friction, and low wear rates.
Syn-Tech Ltd. has also developed NS-4405-FG, a high-capacity
semi-fluid grease designed for helicopter rotor drive trains. This wide
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32
gearsolutions.com
Investigations on the Efficiency

of Worm Gear Drives
By Eva-Maria Mautner, Werner Sigmund, Johann-Paul Stemplinger, and Karsten Stahl
Experimental investigations on different worm gears were conducted on several

test rigs, taking into consideration the influence of different gear ratios, worm
wheel materials, lubricants, and contact pattern on efficiency and load-carrying
capacity. Recommendations for an increase in overall worm gearbox efficiencies
are presented.
DUE TO A WIDE RANGE OF PROPERTIES, WORM
gears are an indispensable element on the current transmission market. Next to a huge gear ratio field in one
gear stage of i = 5 to i = 80, operation with low noise and
vibration is realizable. Furthermore, worm gears provide
the opportunity of self-locking, respectively self-braking.
Despite these benefits, as a result of greater energy awareness, the efficiency of worm gears is in focus. Because
of high sliding velocities, especially at high gear ratios,
gearing losses are a main topic of interest. Other gearbox
concepts with combined spur and bevel gear sets show
smaller gear ratio fields, and therefore the realization
of high gear ratios in only one stage is not possible.
Consequently, fewer components are necessary for worm
gearboxes, which allows savings of assembly and maintenance costs.
The overall efficiency of a gearbox is generally
characterized by the sum of load-dependent gearing,
no-load gearing and bearing, load-dependent bearing,
sealing, and other losses compared to the driving power
(see Equation 1) according to the German Standard
DIN 3996 [1].

Equation 1
Where:
: overall gearbox efficiency / percent
P1 : driving power / W
P V : overall power losses / W
P VZ : load-dependent gearing losses / W
P VL : load-dependent bearing losses / W
P V0 : no-load gearing and bearing losses / W
P VD : sealing losses / W
P VX : other losses / W
In the case of oil-lubricated worm gears, the gearing
losses P VZ are mainly responsible for high overall power
losses P V in particular, at low speeds and high torques.
High overall power losses are explained by a high sliding
motion rate between worm and worm wheel. In order to
reduce gearing losses of worm gears, an ideal combination
of geometry and material pairing, as well as lubrication

and operating conditions, has to be chosen. Therefore,
it is necessary to know to what extent these parameters
influence the efficiency of worm gears.
With the aim of evaluating and optimizing worm gears,
intensive research and development are conducted at the
Gear Research Centre (FZG) of Technische Universitt
Mnchen. Numerous projects have been carried out in
recent years and are constantly in progress. Within these
research projects, various experimental and theoretical
investigations have been executed on worm gears with
different sizes, materials, lubricants, and test conditions.
The tests are conducted primarily with cylindrical worm
gears (flank form ZI) and center distances between a =
65 mm and a = 160 mm.
Main research topics of the current project [2] are
wear and pitting load-carrying capacity as well as efficiency of large-sized worm gears with center distance a
= 315 mm. In the scope of this paper, all experimental
and theoretical results of this project regarding overall
gearbox efficiency are presented in detail. Furthermore,
these results are compared to the insights of other research
projects. Thereby, the influence of different worm gear
geometries, materials, and lubricants, as well as lubrication and operating conditions on efficiency, is considered.
MATERIAL AND METHODS

For the experimental investigations, several worm gear
test rigs, designed and constructed by FZG, are available. For this project [2], the largest worm gear test rig
for worm gears with center distance a = 315 mm is used.
Figure 1 shows a photo and the general principle of this
FZG large-sized worm gear test rig.
The essential component of this test rig is the test
gearbox. In this gearbox, the investigated worm gear is
situated. The test worm wheel is driven by the test worm
shaft with a certain input speed (n1). The worm wheel
is connected to a reverse transfer gearbox with identical
geometry (driven by the worm wheel). This connection
is realized using a double-joint coupling. In order to load
the worm wheel of the test gearbox with a certain output
Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria, Virginia
22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the American Gear Manufacturers
Association (AGMA). This paper was presented October 2015 at the AGMA Fall Technical Meeting in Detroit, Michigan. 15FTM20.
MARCH 2016
33
Figure 1: FZG worm gear test rig for large-sized worm gears with center distance a = 315 mm
torque (T2), a hydrostatic torque motor is connected to the reverse transfer gearbox. This
hydrostatic torque motor infinitely adjusts
the respective load. The bracing cycle of the
test rig is closed by a summation gearbox.
Consequently, the direct current motor only
has to feed in the occurring overall power
losses.
In the scope of this research project [2],
large-sized worm gears with center distance a
= 315 mm are analyzed regarding their overall
gearbox efficiency, as well as wear and pitting
behavior at different operating and lubrication conditions. The overall efficiency of the
tested worm gearbox is the result of input/

output speeds and input/output torques.
These are measured continuously by torquemeasuring shafts at input and output of the
investigated worm gearbox (see Figure 1).
The used torque-measuring shafts have a
measuring accuracy of 0.5 percent (input),
respectively 1.0 percent (output). Wear and
pitting load-carrying capacity analysis are
executed regularly. Results regarding pitting
load-carrying capacity are obtained by the
assessment of periodically documented flank
pictures of the worm wheel. To measure wear
on the investigated worm wheel, a transmis-
sion error measuring system (see Figure 1)

is used.
The investigated worm gearboxes are cylindrical worm gears with flank form ZI (righthanded thread). The present large-sized worm
gears have a center distance of a = 315 mm
and a gear ratio of i = 10.25. In Table 1, all
important gear data of the investigated test
gearboxes is listed.
The investigated worm gears are made of
case-hardened steel worms (20MnCr5) and
centrifugally casted copper-tin bronze worm
wheels with nickel (CuSn12Ni2-C-GZ).
The experimental investigations are carried
out at various input speeds n1 and output
torques T2. This serves to evaluate wear and
pitting load capacity as well as efficiency of
worm gears of this size at different operating
conditions. The gained results are used to
verify current calculation methods for worm
gears in the German Standard DIN 3996 [1].
The conducted test program in the scope of
this project [2] is shown in Table 2. Altogether,
four tests are executed at the flanks (fore and
rear flanks) of two worm gears.
Running-in
Table 1: Gear data of investigated test gearboxes
Table 2: Test program on large-sized worm gears (CuSn12Ni2-C-GZ worm wheel with 20MnCr5 worm shaft,
a = 315 mm, i = 10.25)
34
gearsolutions.com
To smooth tooth flanks and enlarge the contact pattern, a running-in is carried out at
the beginning of each test. The running-in
process is executed at a low input speed of n1
= 300 min-1 in order to cause a high wear rate
and therefore a fast enlargement of contact
pattern. Meanwhile, the output torque is
increased step-by-step (T2 = 2 ... 14.7 kNm).
During running-in, periodic wear/efficiency
measurements are executed at an input speed
of n1 = 300 min-1 and an output torque of T2
= 10 kNm (measurement condition 1).
The influence of different lubricants on
wear load-carrying capacity and efficiency
during running-in is evaluated by testing
diverse oils (see Table 2). All tests are conducted with injection lubrication (JOil =
80C). The synthetic oil Klbersynth GH
6-460 (polyglycol, ISO VG 460) is used for
the running-in of tests 1 and 2. A polyglycol
(Klbersynth GEZ 6-220) is also used for test
3. However, the viscosity class is hereby lower
(ISO VG 220). Furthermore, in test 4, a different oil type is utilized. In contrast to tests
1, 2, and 3, running-in is carried out with the
mineral oil Renolin CLP 460 (ISO VG 460).
The running-in process of each test is finished by reaching an almost complete contact pattern (contact area ft 90100 percent). In the present project with large-sized
worm gears, running-in lasts approximately
between 300 and 550 hours.
Main Test Run
After the running-in process, the main test

run takes place. For the main tests, two different input speeds are examined to estimate
wear behavior and its influence on pitting
development. The input speed varies between
n1 = 1200 min-1 (tests 1 and 3) and n1 = 300
min-1 (tests 2 and 4). During all tests, the
worm wheel is loaded with an output torque
of T2 = 14.7 kNm (n1 = 1200 min-1: measurement condition 2a; n1 = 300 min-1: 2b). This
corresponds to 133 percent (n1 = 1200 min-1),
respectively 65 percent (n1 = 300 min-1) of the
nominal torque T2N according to [4].
All test runs are lubricated with the polyglycol Klbersynth GH 6-460 (ISO VG 460).
The type of lubrication is injection lubrication at an injection temperature of JOil = 80C
and an injection amount of 25 l/min.
To analyze wear behavior of this kind of
large-sized worm gear, regular measurements
are carried out during the main test run with
the transmission measuring system (see Figure
1). Hereby, the output torque is T2 = 10 kNm
and the input speed is n1 = 300 min-1 (measurement condition 3). Each wear measurement
during test runs lasts exactly one hour.
Table 3: Measurement conditions for efficiency evaluation
Table 4: Initial load contact patterns (T 2 = 10 kNm) of conducted tests
operating and lubrication conditions, geom- process at n1 = 300 min-1 and with gradually
enhanced torque T2, a higher wear rate is
etry, and material.
present. This causes an enlargement of conInfluence of Contact Pattern and Roughness tact. At the end of running-in, tests 1 and 4
During the experimental investigations, the show a contact area of approximately ft = 90
influence of varying sizes of contact pat- percent. In spite of an extended running-in
tern on efficiency is considered in detail as process, test 3 only reaches ft = 76 percent.
well. For the determination of the contact A small contact pattern of ft = 68 percent is
area ft, all worm wheel flanks are photo- purposely reached for test 2 in order to evalugraphed regularly. The evaluation of the ate wear and pitting behavior of incomplete
contact pattern development of each flank contact patterns.
is performed with a specially developed,
In the case of test 1, which is exemplarily
color-based MatLab program.
shown in Figure 2, first efficiency measureAt the beginning of the experimental inves- ments (measurement condition 1) are carried
tigations, the contact pattern of each test out after 0.3 million load cycles. At this time,
is adjusted. All initial contact patterns are an average contact area of ft = 86 percent is
shown in Table 4.
already given. This leads to an initial overall
Each contact area ft corresponds to the gearbox efficiency of 93.6 percent.
mean contact area of all worm wheel flanks
In the further course of the running-in
of one test. On average, both tests on the process of test 1, an enlargement of contact
fore flank (tests 1 and 4) show contact areas pattern from ft = 86 percent to ft = 93 perof 65 to 75 percent. On the rear flank (tests cent after 0.5 million load cycles is realized.
2 and 3), an average contact area of 60 per- As with the contact pattern, an increase in
cent is documented. During the running-in overall gearbox efficiency from 93.6 per-
Measurement Conditions
Table 3 gives an overview of all measurement

conditions for the documentation of overall
gearbox efficiency during running-in and the
main test run.
RESULTS
In the following section, the results of all
executed tests on large-sized worm gears in
the course of this research project [2] are
introduced and explained in detail. At the
same time, the influence of various factors
on overall gearbox efficiency is described in
particular. These influencing factors concern
Figure 2: Influence of contact areas on overall gearbox efficiency during running-in of test 1
MARCH 2016
35
cent to 95.5 percent is documented. After an

additional 0.4 million load cycles, an overall
gearbox efficiency of = 96.0 percent is
measured ( ft = 96 percent). Consequently, by
the contact area enlargement of 10 percent, an
efficiency improvement of = 2.4 percent
is measured. This conclusion corresponds to
the results made by [5] and [6] (see Figure
3). With an increasing contact area, the overall gearbox efficiency improves during the
running-in of worm gears.
Besides the enlargement of the contact area,
running-in is accompanied by a smoothing of
gear flanks. The roughness of the worm wheel
flanks adjusts to the roughness of the worm
flanks. It is therefore essential to have low worm
flank roughness in order to reduce the coefficient of friction and therefore power losses.
The influence of arithmetic mean roughness Ra is considered as well in the German
Standard DIN 3996 [1]. In Figure 4, a schematic, mathematical course of the degree of
losses P V/P1 is shown for different roughness
values. Therefore, a standard worm gear with
center distance a = 100 mm and i = 20.5
(CuSn12Ni2-C-GZ/16MnCr5, injection
lubrication, polyglycol) is used.
The degree of losses is the ratio of overall
power losses P V to driving power P1 the
higher the degree of losses, the lower the
overall gearbox efficiency (see Equation 1).
The figure illustrates the reduction of the
degree of losses with lower arithmetic mean
roughness values. The share of gearing losses
P VZ decreases due to lower coefficients of
friction. For the other losses, there is no
dependence of the arithmetic mean roughness
Ra. The sealing losses P VD contributes the
smallest share of degree of losses.
Next to the size of contact area, the position
of contact pattern can influence efficiency.
According to Niemann and Winter [5], contact patterns positioned at inlet side cause
higher power losses than contact patterns
at outlet side. Wakuri [6] measured about 6
percent lower efficiencies for worm gears with
contact patterns positioned at inlet side than
with contact patterns at outlet side. This is
explained by higher coefficients of friction
at inlet side.
The coefficient of friction as well as the
build-up of lubricating film of worm gears
depends on sum velocity S [5]. To evaluate
friction behavior, the ratio of sliding velocity to sum velocity (g/S) is used according
to Niemann [5] and Wilkesmann [7]. With
a decreasing ratio, the coefficient of friction
decreases as well [5]. The distribution of sum
velocities and sliding velocities can be calculated for all kinds of worm gear geometries
36
gearsolutions.com
Figure 3: Development of contact pattern and efficiency during running-in [5, 6]
Figure 4: Influence of arithmetic mean roughness Ra on degree of losses P V/P1 of worm gears
(CuSn12Ni2-C-GZ/16MnCr5, a = 100 mm, i = 20.5, injection lubrication) according to DIN 3996 [1]
Figure 5: Amount of sum velocities (left) and sliding velocities (right) (test 1: n1 = 1200 min -1, T 2 = 14.7 kNm)
with the software SNESYS [8] (in particular,

with the included program SNETRA). Next to
this, SNETRA [8] delivers a course of contact
lines, contact pattern under load and no-load,
as well as distribution of equivalent radius of
curvature, Hertzian stresses, and lubricant
film thickness. It is also possible to simulate
complete and incomplete contact patterns. To
of lubricant film thickness (test 1:
simulate present investigations on the large- Figure 6: Distribution
n1 = 1200 min -1, T 2 = 14.7 kNm)
sized worm gear with center distance a = 315
mm in SNETRA, the contact patterns after
Higher coefficients of friction at inlet side
running-in are used. Figure 5 shows the results than those at outlet side are explained by
regarding the amount of sum velocities (left) lower sum velocities at this side of the worm
and sliding velocities (right) achieved for test 1. wheel (see Figure 5). In the area where low
sum velocities occur, low lubricant film thicknesses arise. Thus, worm gears
with contact patterns at outlet side show better efficiencies. The distribution
of lubricant film thickness is illustrated in Figure 6.
Influence of Input Speed
Sum and sliding velocity mainly depend on current input/output speed. In

Figure 7, a typical course of measured overall gearbox efficiency for the
test gearbox during the main run of test 1 at the input speed of n1 = 1200
min-1 (measurement condition 2a) is illustrated.
Thereby, the worm gear is loaded with an output torque of T2 = 14.7 kNm at
an input speed of n1 = 1200 min-1 (measurement condition 2a). It is lubricated
with the polyglycol Klbersynth GH 6460. During the measurement, a constant overall gearbox efficiency of approximately = 96 percent is documented.
Further measurements during test 1 result in similar values between 94.6
percent and 96 percent. The test at the same operating conditions (test 3
according to Table 2) shows a comparable course of overall gearbox efficiency
Figure 7: Representative measurement of overall efficiency of test
of up to = 94.6 percent during the main test run.
gearbox (test 1)
For the lower input speed of n1 = 300 min-1
with same output torque of T2 = 14.7 kNm
(tests 2 and 4, measurement condition 2b),
slightly lower efficiencies of = 94.094.5
percent are achieved than for test 1 ( =
94.696.0 percent, measurement condition
2a: n1 = 1200 min-1). This is explained by
lower sum velocities and an unfavorable lubrication film formation. Lower sum velocities
lead to an increase in coefficient of friction
and therefore to a decrease in efficiency.
The high influence of input speed on
worm gearbox efficiency is considered as
well in DIN 3996 [1]. Figure 8 illustrates
a schematic, mathematical course of the
degree of losses P V/P1 via the input speed
n1 of a standard worm gear (CuSn12Ni2C-GZ/16MnCr5, a = 100 mm, i = 20.5,
injection lubrication, polyglycol) according
to DIN 3996 [1].
Figure 8: Influence of input speed n1 on degree of losses P V/P1 of worm gears (CuSn12Ni2-C- GZ/16MnCr5, a =
Hereby, lower speeds lead to higher degrees
100 mm, i = 20.5, injection lubrication, polyglycol) according to DIN 3996 [1]
of losses. The share of gearing losses PVZ
increases due to higher coefficients of friction with lower input speeds. According to
DIN 3996, the shares of bearing losses PVL
and no-load losses PV0 decrease with a slower
rotating worm. This is explained by lower
input power P1, which leads to a higher
degree of losses PV/P1 (see Equation 1).
Consequently, large-sized worm gears have
a similar behavior regarding the influence of
input speed on overall gearbox efficiency.
Influence of Output Torque
Figure 9: Influence of output torque T 2 on degree of losses P V/P1 of worm gears (CuSn12Ni2-C- GZ/16MnCr5, a =
100 mm, i = 20.5, injection lubrication, polyglycol) according to DIN 3996 [1]
Next to speed, the present output torque T2

influences the overall efficiency of worm
gears [5]. Usually, lower loads lead to lower
efficiency values [5]. In the scope of this
project [2] with large-sized worm gears, the
same behavior is documented. With a lower
load and the same input speed during the
main test measurements of tests 2 and 4
(measurement condition 3: T2 = 10 kNm, n1
MARCH 2016
37
= 300 min-1), slightly lower efficiencies ( = 0.10.7 percent) toward

the results with T2 = 14.7 kNm and n1 = 300 min-1 (measurement
condition 2b) are recorded. Figure 9 shows a schematic, mathematical course of the degree of losses P V/P1 via the output torque T2 for
a standard worm gear in conformity with Figure 4 and Figure 8.
In general, the degree of losses P V/P1 increases with a decreasing output torque T2. The absolute values of the no-load losses P V0
and the sealing losses P VD are not influenced by the output torque.
Because of a decreasing driving power P1, the shares of P V0 and P VD,
however, are becoming bigger. With respect to the load-dependent
gearing losses P VZ, a decrease of its share of the degree of losses results
in lower torque. Load-dependent bearing losses P VL have an almost
constant share of the degree of losses.
An exemplary efficiency field for worm gears at different operating
conditions is shown in Figure 10. The results are taken from former
and actual experimental investigations on steel-bronze worm gears,
with center distances a = 65, 100, 160, and 315 mm, executed at FZG
by [9], [10], and [2]. All tests are injection-lubricated with polyglycol
(ISO VG 220 or 460).
The figure emphasizes the described influence of speed and load
on overall efficiency of steel-bronze worm gears. Depending on the
combination of input speed n1 and output torque T2, overall efficiencies between = 84 percent and = 95 percent are reached. For a
worm gear with center distance a = 100 mm and ratio i = 10.3, for
example, Rank [9] measured an overall gearbox efficiency of =
94.7 percent at the operating conditions n1 = 2900 min-1 with T2 =
1180 Nm.
Figure 10: Test results for overall gearbox efficiency according to [9], [10], and [2]
Influence of Oil Viscosity
To evaluate the influence of oil viscosity, efficiency results at the

end of running-in of tests 1 and 2 (polyglycol ISO VG 460) are
compared to those of test 3 (polyglycol ISO VG 220) (see Table 2).
All three measurements are conducted at the same input speed n1
= 300 min-1 and output torque T2 = 10 kNm (measurement condition 1). According to Niemann [5], oils with higher viscosity lead to
higher no-load losses but lower power losses due to better lubricant
film formation. In the present investigations, slightly higher overall
gearbox efficiency ( 12 percent) can also be measured with
higher oil viscosity.
In the present German Standard DIN 3996 [1], the influence of
different oil viscosities on the efficiency of worm gears is currently
not taken into account.
Figure 11: Ubbelohde-Walther diagram of investigated lubricants
Influence of Oil Type
Next to oil viscosity, oil type influences worm gear efficiency significantly. In general, synthetic lubricants (e.g., polyglycols, polyalphaolefins, or ester oils) lead to lower coefficients of tooth friction in
comparison to mineral oils [5]. Low power losses and therefore better
efficiencies come along with low coefficients of friction [5]. The influence of the oil type is more significant with higher sliding velocities.
In the present tests, the impact of different oil types is clear.
Therefore, efficiency values measured at the end of running-in of test
3 and test 4 are compared. Test 3 is lubricated with the polyglycol
GEZ 6220 during running-in, whereas for the running-in of test
4, the mineral oil CLP 460 is used. Both tests are conducted at a
lubricant injection temperature of JOil = 80C. This leads to similar
kinematic viscosities for GEZ 6220 (test 3) and CLP 460 (test 4)
according to Figure 11. In addition, comparable dynamic viscosities
also result according to the German Standard DIN 3996 [1]. An
influence of different oil viscosities can therefore be excluded.
38
gearsolutions.com
Figure 12: Influence of oil type on degree of losses P V/P1 of worm gears
(CuSn12Ni2-C- GZ/16MnCr5, a = 100 mm, i = 20.5, injection lubrication) according to
DIN 3996 [1]
Influence of Pitting
Table 5: Overall gearbox efficiency at the end of running-in
Table 6: Overall gearbox efficiency during the main test run
Table 7: Development of pitting area on worm wheel flanks over load cycles wheel N L of test 1
With the mineral oil CLP 460, an overall

gearbox efficiency of only = 91 percent
is measured at an input speed of n1 = 300
min-1 and an output torque of T2 = 10 kNm
(measurement condition 1) compared to =
93.7 percent with the lubricant GEZ 6220.
Consequently, the reduction of efficiency is
explained by the use of mineral oil.
The influence of oil type on efficiency
is also considered in the German Standard
DIN 3996 [1]. Worm gears lubricated with
mineral oils show higher degrees of losses
than worm gears lubricated with polyglycol.
Figure 12 illustrates the schematic, mathematical influence of oil type on degree of
losses for a standard worm gear (CuSn12Ni2C-GZ/16MnCr5, a = 100 mm, i = 20.5,

injection lubrication, n1 = 1500 min-1, T2 =
680 Nm).
The share of gearing losses PVZ in the degree
of losses is especially higher. This is explained
by higher coefficients of friction for gears
lubricated with mineral oils. The other shares
in the degree of losses are not influenced by
the oil type, pursuant to DIN 3996 [1].
All described test results from this project
[2] regarding overall worm gearbox efficiency
are summarized in Table 5 for the end of
running-in and in Table 6 for the results
during the main test run.
During all conducted tests according to Table

2, pitting on the worm wheel flanks occurs.
Rank [9] and [11] determines in his examinations on bronze worm wheels paired with
case-hardened worms, mainly with center
distance a = 100 mm a characteristic of
pitting development. According to Rank, the
lifetime of bronze worm wheels is divided
into three stages. This typical three-phase
course is illustrated in Figure 13 (CuSn12NiC-GZ/16MnCr5, a = 100 mm, i = 10.33,
injection lubrication, polyglycol, n1 = 1500
min, T2 = 1180 Nm).
In general, the pitting development is characterized by different specific values. APm is
the average of the pitting area of all worm
wheel flanks. APmax describes the maximum
pitting area of all worm wheel flanks. The
value AP10 is the mean pitting area of 10
percent of the most damaged worm wheel
teeth. AP10 represents the decisive parameter
for the description and calculation of pitting
development.
At the beginning of the service life of a worm
gear, first pits occur in the area of highest worm
wheel flank pressures. This section is called the
no pittings stage (phase I) [11]. After reaching
AP10 = 2 percent, pits grow approximately in
a linear way. During this period called the
pitting growth stage (phase II) pitting area
increases up to a maximum value (AP10,max).
After reaching this maximum, pitting area
decreases again, due to high wear during the
wear stage (phase III).
In accordance with the examinations of
Rank [9] and [11], the present large-sized,
bronze worm wheels show the typical threephase course. An exemplary course of pitting
Figure 13 (above): Pitting development according to Rank [9]

Figure 14 (right): Pitting development for test 1 (n1 = 1200 min-1, T 2 = 14.7 kNm)
MARCH 2016
39
Figure 15: Overall gearbox efficiency over load cycles wheel (test 1)
damage documented during present examinations [2] is shown in Figure 14 for test 1.
Table 7 illustrates the corresponding photos
of pitting damage on worm wheel flanks after
different load cycles NL .
After NL = 2.8 million load cycles, a pitting
area of AP10 = 2 percent and consequently the
end of phase I is reached. Subsequently, pitting area increases further during the pitting
growth stage (phase II) until a maximum of
AP10,max = 46 percent is reached. As with the
examinations executed by Rank, a decrease
of pitting area in phase III is documented.
Despite an increasing pitting area of up to
AP10 = 46 percent (phase II), no significant
change in overall gearbox efficiency is documented, as it is shown for test 1 in Figure 15.
In Figure 15, the results of all efficiency
measurements of test 1 in accordance to Table
3 are illustrated. During running-in, periodic
wear/efficiency measurements (measurement
condition 1) are executed at an input speed of
n1 = 300 min-1 and an output torque of T2 =
10 kNm. For the main test, the input speed is
n1 = 1200 min-1 with an output torque of T2
= 14.7 kNm (measurement condition 2a). To
analyze wear behavior of this kind of largesized worm gear, regular measurements are
carried out during the main test run with the
transmission measuring system (see Figure 1).
Hereby, the output torque is T2 = 10 kNm and
the input speed is n1 = 300 min-1 (measurement condition 3). Each wear measurement
during test runs lasts exactly one hour.
The same behavior regarding pitting development, as well as overall gearbox efficiency,
is documented for the other conducted tests
2, 3, and 4. In tests 2 and 4, a different input
speed of n1 = 300 min-1 (measurement condition 2b) is examined to estimate wear behavior and its influence on pitting development.
The results for overall gearbox efficiency, in
dependence of the load cycles of the worm
wheel, are shown in Figure 16 (test 2), Figure
17 (test 3), and Figure 18 (test 4).
At the same time, material is removed
from the worm wheel flanks due to wear.
The intensity of wear varies during the different pitting phases. As well as for pitting,
no influence of wear on overall gearbox efficiency is documented during all conducted
experimental investigations.
Efficiency Calculation with SNDIN [8]
40
gearsolutions.com
Next to the described simulation with

SNESYS [8] (previously discussed), the
included program SNDIN allows a loadcarrying capacity and efficiency calculation
according to DIN 3996 [1] with SNDIN. For
the present large-sized worm gear, a calcula-
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Influence of Center Distance and Lead Angle
To improve gearbox efficiency, a right choice

of worm gear geometry is important. Niemann
and Winter [5] particularly show a correlation
between the ratio of diameter to center distance dm1/a, the lead angle m, the coefficient
of friction z, and the gearing efficiency z.
Higher gearing efficiency z is accompanied
by a decreasing ratio of diameter to center distance dm1/a [5]. This, however, results in lower
safety factors for pitting and deflection. With
an increasing lead angle m, the coefficient of
friction gets lower, which leads to higher gearing
efficiencies (see Figure 19) [12].
Influence of Gear Ratio
Table 8: Efficiency calculation with SNDIN [8] according to DIN 3996 [1]
tion in SNDIN was undertaken with all used lubricants and investigated operating conditions. The calculated overall gearbox efficiency results are shown in Table 8.
For the input speed of n1 = 300 min-1, no influence of both output torques on calculated efficiency is recognizable. The effect of different oil viscosities is not considered yet in DIN 3996 [1].
Altogether, a good correspondence between the calculated values and the experimentally
gained overall gearbox efficiencies is determined. Whereby, the measured efficiencies are
slightly better than the calculated values. In total, efficiencies of up to 96 percent can be
gained in these worm gearboxes.
FURTHER INFLUENCING FACTORS ON WORM GEAR EFFICIENCY

Next to the influencing factors on overall worm gearbox efficiency, described earlier, by
mainly using the results of the project on large-sized worm gears [2], further variables can
result in an optimization of efficiency.
Figure 19: Influence of lead angle on gearing efficiency [12]
42
gearsolutions.com
Furthermore, there is an influence of varying

gear ratio i on overall efficiency of worm gears.
A decrease in gear ratio i (multi-start worm) can
be accompanied with an improvement of efficiency [5]. According to Niemann and Winter
[5], overall gearbox efficiencies of = 96 percent
(gear efficiency z = 98 percent) are documented
with small ratios (i = 5) at an input speed of n1 =
1500 min-1 (lubrication with mineral oil).
Excessively high values of gear ratio can result
in self-locking worm gears (with driving worm
z < 50 percent). Figure 20 illustrates this influence of different gear ratios i on overall gearbox
efficiency according to [13].
In the scope of Weisels investigations [10],
he carried out test runs at the same largesized test rig (see Figure 1). These worm gears
(CuSn12Ni2-C-GZ/16MnCr5, a = 315 mm,
m = 14.04) have a higher gear ratio of i =
20.5 compared to the tests conducted in [2] (i
= 10.25). The main test runs are executed at T2
= 15.75 kNm and n1 = 1500 min-1. Despite the
difference in lead angle m and input speed,
similar sliding velocities are resulting ([2]: vgm
= 8.5 m/s; [10]: vgm = 8.7 m/s). Furthermore,
similar mean flank stresses (sHM = 343 N/mm2)
Figure 20: Influence of ratio on overall efficiency of worm gears (driving worm, flank
form ZI, lubrication with mineral oil) according to [13]
Figure 21: Influence of worm wheel material on degree of losses P V/P1 of worm
gears (a = 100 mm, i = 20.5, dip lubrication, polyglycol) according to DIN 3996 [1]
Figure 22: Influence of type of lubrication on degree of losses P V/P1 of worm gears
(CuSn12Ni2-C-GZ/16MnCr5, a = 100 mm, i = 20.5, polyglycol) according to DIN 3996 [1]
according to DIN 3996 [1] are calculated. In comparison with test 1

(measurement condition 2a) previously described, lower overall gearbox
efficiencies of = 93 percent ( = 23 percent) are documented by Weisel
[10] during these main test runs. As a consequence, this fact is explained,
for example, by the different gear ratios as well as the used lubricant,
which has a lower viscosity (polyglycol, ISO VG 220) compared to test
1 (polyglycol, ISO VG 460).
These different types of lubrication affect overall gearbox efficiency.

Figure 22 shows the theoretical degree of losses depending on the type of
lubrication for a standard worm gear (CuSn12Ni2-C-GZ/16MnCr5, a =
100 mm, i = 20.5, polyglycol, n1 = 1500 min-1, T2 = 680 Nm) according
to DIN 3996 [1].
With injection lubrication, the degree of losses is slightly higher than
with dip lubrication. This is explained by a higher share of gearing losses
PVZ. An influence of lubrication type on the other losses has not yet been
Influence of Profile Flank Form
taken into account in DIN 3996 [1]. Especially with regard to no-load
According to Niemann and Winter [5], higher efficiencies are reached by losses PV0, the type of lubrication can have considerable impact. In order
using concave profile flank forms (ZH respectively ZC). This is explained to realize injection lubrication, an oil pump is necessary. This leads to
by a better osculation and a steeper course of the contact lines, which further losses, which are not considered in the comparison in Figure 22.
causes a better lubricant film and fewer power losses. Heilemann [14]
shows gearing efficiencies for worm gears with profile flank form ZC Influence of Type of Lubricant
and an improved variant of it. He indicates overall gearbox efficiencies Usually, worm gears are lubricated with oil. In addition to oil lubricaof up to 97 percent.
tion, grease can also be used for the lubrication of worm gears in certain
Furthermore, globoid worm gears (globoid worm with globoid worm applications. Here, however, it is important to note that they are mostly
wheel) show similar efficiencies as cylindrical worm gears with ZI profile only applicable at very low circumferential velocities (< 8 m/s) [5]. Monz
flank form [5]. Helical worm gear units (globoid worm with spur wheel) [12] investigates worm gears lubricated with different greases. He points
are theoretically similar to ZI worm gears regarding power losses [5]. out the possibility of increasing efficiency of worm gears by using greases
However, the manufacturing of globoid worms is more complicated.
especially greases of NLGI class 2 instead of the corresponding
base oils. This is explained by a reduction of no-load losses PV0, in parInfluence of Material
ticular, at very low speeds and small worm gear sizes in comparison to
Due to a high sliding motion rate, usually hard worm shafts are paired oil lubrication. However, grease-lubricated worm gears show higher wear
with soft worm wheels. With regard to efficiency, worm gears with wheels due to less favorable heat dissipation and therefore higher thermal loads,
consisting of Cu-Sn-bronze and worms consisting of case-hardened steel opposed to oil. Further potentials of grease-lubricated worm gears with
tend to be better than wheels made of cast iron, Al-bronze, or special regard to thermal performance, wear behavior, and efficiency are currently
brass [5]. This can be explained by better sliding properties of bronze being examined in [15].
worm wheels [15]. Figure 21 illustrates this influence of materials on
the degree of losses for worm wheels made of bronze (CuSn12Ni) and CONCLUSION
cast iron (GJS-400) according to DIN 3996 [1] (a = 100 mm, i = 20.5, Worm gears are still a fundamental component in the field of high transdip lubrication, polyglycol). The figure emphasizes the higher shares of mission gears (i = 1 to 80). Overall worm gearbox efficiencies of up to
gearing losses PVZ in the degree of losses for cast iron worm wheels due = 96 percent are realizable. This was confirmed at FZG in the scope
to higher coefficients of friction.
of experimental and theoretical investigations on large-sized worm gears
((CuSn12Ni2-C-GZ/20MnCr5, a = 315 mm, i = 10.25) [2]. In some
Influence of Type of Lubrication
cases, even higher efficiency values than = 96 percent are achievable.
By using oil, different types of lubrication are realizable. Next to injection
With regard to an optimization of worm gear efficiency, different
lubrication, dip lubrication is a typical lubrication type for worm gears. influencing factors were investigated during the experimental tests. In
MARCH 2016
43
this paper, these factors are described in detail

wheel with case-hardened worm tends to
have higher efficiency than wheels made
and are compared to further experimental and
of cast iron, aluminum bronze, or special
theoretical results. The most important influbrass, because of lower gearing losses.
encing factors on worm gear efficiency are:
Operating conditions:
Geometry:
High input speeds n1 and high output
Higher gearing efficiency is accompanied
torques T2 usually lead to an increase in
by a decreasing ratio of diameter dm1 to
center distance a.
overall gearbox efficiency.
An increasing lead angle m leads to Lubricant:
higher gearing efficiencies.
Oils with high viscosity result in higher
A decrease in gear ratio i can result in an
no-load losses but lower load power losses
improvement of efficiency.
due to better lubricant film formation in
Material pairing:
gears and bearings.
The pairing of copper-tin bronze worm
With synthetic oil types (especially polygly-
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44
gearsolutions.com
cols), higher efficiency values are reached in

comparison to mineral oils (for the pairing
of bronze worm wheel with case-hardened
worm).
According to DIN 3996 [1], slightly higher
losses are calculated with the lubricationtype injection lubrication than with dip
lubrication. This is explained by higher
gearing losses. The influence of lubrication type on the other losses is actually not
considered.
Next to oil, grease can be used for the
lubrication of worm gears at special operating conditions. Especially at very low input
speeds, grease lubrication (e.g., greases of
NLGI 2) often has a reducing effect on
no-load losses in comparison to oil.
Contact pattern:
An enlargement of contact pattern mostly
correlates with an increase in efficiency.
Contact patterns positioned at inlet side
cause higher power losses than contact
patterns at outlet side due to higher coefficients of friction at inlet side.
Roughness:
Low worm flank roughness can reduce
the coefficient of friction and therefore
power losses.
ACKNOWLEDGEMENTS
This research project was sponsored by
Forschungsvereinigung Antriebstechnik e.V.
(FVA).
REFERENCES
1. DIN 3996: Tragfhigkeitsberechnung von
Zylinder-Schneckengetrieben mit sich rechtwinklig kreuzenden Achsen. Deutsches Institut fr
Normung e. V., Beuth Verlag, 2012.
2. Mautner,
E.-M.
Verschleiund
Grbchentragfhigkeit von groen ZylinderSchneckengetrieben mit optimierter Radbronze.
Forschungsvereinigung Antriebstechnik e.V.,
Frankfurt, FVA 503/II, 2015.
3. DIN 3975: Begriffe und Bestimmungsgren
fr Schneckengetriebe mit sich rechtwinklig
kreuzenden Achsen. Deutsches Institut fr
Normung e. V., Beuth Verlag, 2002.
4. Henschel Antriebstechnik. MUTAXSIMPLEX Radstze. Company brochure,
March 2011.
5. Niemann,
G.
and
Winter,
H.
Maschinenelemente: Schraubrad-, Kegelrad-,
Schnecken-, Ketten-, Riemen-, Reibradgetriebe,
Kupplungen, Bremsen, Freilufe. Springer
Verlag, Berlin Heidelberg, Germany, Volume 3,
Edition 2, 1983.
6. Wakuri, A. and UENO, T. The lubrication of
worm gears. ISME 1967, Semi-International
Symposium, Tokyo, 4th September 1967.
7. Wilkesmann, H.: Berechnung von

Schneckengetrieben mit unterschiedlichen
Zahnprofilformen. Dissertation, FZG TU
Mnchen, 1974.
8. Lutz, M. Berechnungsprogramm zur
Ermittlung des Tragbildes zwischen Schnecke
und Schneckenrad. Forschungsvereinigung
Antriebstechnik e.V., Frankfurt, FVA 252, Heft
500, 1996.
9. Rank, B. Untersuchungen zur Grbchenbildung
bei Zylinder-Schneckengetrieben. Dissertation,
FZG TU Mnchen, Germany, 1996.
10. Weisel, C. Verschlei- und Grbchentragfhigkeit
von groen Zylinderschneckengetrieben mit
optimierter Radbronze. Forschungsvereinigung
Antriebstechnik e.V., Frankfurt, FVA 503/I, Heft
892, 2009.
11. Hhn, B.-R., Michaelis, K., Rank, B. and
Steingrver, S. Investigation of the pitting resistance of worm gears. JSME, Fukuoka, Japan,
November, 2001.
12. Monz, A. Tragfhigkeit und Wirkungsgrad
von Schneckengetrieben bei Fettschmierung.
Forschungsvereinigung Antriebstechnik e.V.,
Frankfurt, FVA 522/I, Heft 931, 2010.
13. Dubbel: Taschenbuch fr den Maschinenbau.
Springer Verlag, Berlin Heidelberg, Germany,
Edition 23, 2011.
14. Heilemann, J. and Leoni, P. Wirkungsgrad
moderner CAVEX-Schneckengetriebe fr die
Applikation als Schwerleistungsgetriebe. Aalener
Kolloquium Antriebstechnische Anwendungen.
Aalen, Germany, Mrz, 2014.
15. Steingrver, K. Untersuchungen zu Verschlei,
Verlustgrad und Fressen bei ZylinderSchneckengetrieben. Dissertation, FZG TU
Mnchen, 1993.
16. Reitinger, E.-M. and Monz, A. Tragfhigkeit
und Wirkungsgrad von Schneckengetriebe
bei Fettschmierung. Forschungsvereinigung
Antriebstechnik e.V., Frankfurt, FVA 522/II, 2014.
ABOUT THE AUTHORS: Eva-Maria Mautner
is currently a research associate and Ph.D.
student at the Gear Research Centre (FZG)
at the Technische Universitt Mnchen (TUM)
in Germany, specializing in efficiency and
load-carrying capacity of worm gears with
regard to geometry, lubrication, and operating
conditions. She studied mechanical engineering
at the Technische Universitt Mnchen. She is
currently working on her Ph.D. thesis on Wear
and pitting load carrying capacity of large-sized
worm gears.
Werner Sigmund studied mechanical engineering
at the Technische Universitt Mnchen (TUM)
in Germany. In 2010, he began working as a
research associate at the Gear Research Centre
(FZG) at the Technische Universitt Mnchen
(TUM). Since 2014, Sigmund has been a team
leader for worm gears at FZG. In 2015, he
finished his doctoral thesis on Investigation and
simulation of the wear behavior of worm gears with
local contact pattern.
Dr.-Ing. Johann-Paul Stemplinger has been responsible for testing automatic gearboxes at AUDI AG
since 2015. Until December 2015, he worked as a research group manager at FZG, Gear Research
Centre, Technische Universitt Mnchen in Germany and was responsible for the groups gearbox
efficiency, worm, bevel, and hypoid gears. In 2012, he was responsible for gearbox efficiency as a
team leader at FZG. Stemplinger holds a M.Sc. in mechanical engineering of Technische Universitt
Mnchen and finished his doctoral thesis in the field of tribology of gear contacts at FZG in 2013. He
has authored over 20 publications including four patents in the field of powertrain and transmission
focusing on tribology and lubrication of gears. He received the Oskar Karl Forster and the Prof. Dr.
Wilhelm Wittmansches scholarship in 2008.
Prof. Dr.-Ing. Karsten Stahl studied mechanical engineering at the Technische Universitt Mnchen
before serving as research associate at the Gear Research Centre (FZG) at the Technical University
Munich. In 2001, he received his Ph.D. in mechanical engineering and started as gear development
engineer at the BMW group in Dingolfing, subsequently named head of Prototyping, Gear Technology &
Methods in 2003. From 20062009, he changed to the BMW/MINI plant in Oxford, U.K., first as group
leader, and in 2007, as department leader for validation driving dynamics and powertrain. In 2009,
Stahl returned to Munich and was responsible for predevelopment and innovation management within
BMW Driving Dynamics and Powertrain. In 2011, Stahl was named head of the Institute for Machine
Elements and the Gear Research Centre (FZG) at the Technische Universitt Mnchen.
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EALs provide value to offshore and other vessels
46
gearsolutions.com
Shear Stability Is Key to Proper

EAL Gear Oil Selection
By Ben Bryant and Craig Desrochers
To prevent failures of bearings and gears, careful selection of EALs for use in
marine components, combined with a good oil sampling program, are necessary.
SELECTING A GEAR OIL FOR USE IN MARINE
thrusters or a stern tube lubricant for use with propeller
shaft bearings is typically based on analyzing price and
performance characteristics of the lubricant and its availability. Now, with the implementation of the 2013 Vessel
General Permit, this analysis must be expanded to include
environmentally acceptable lubricants (EALs) that meet the
new EPA standards. To meet environmental requirements,
EALs are blended from base oils other than mineral oil.
They still meet the same lubricant objective: to provide
long-term equipment protection. It is worthwhile, however,
to focus on how the new EALs meet one particular criterion
for analysis their ability to resist shearing under load.
APPLICATIONS REQUIRING EALS

The 2013 Vessel General Permit requires that lubricants
used in applications with an oil-to-sea interface meet specific requirements for biodegradability, toxicity, and bioaccumulation. The permit allows for a phased transition to
EALs based on product availability, dry-dock schedules,
and approval of the lubricant from the original equipment
manufacturer (OEM) of the application. OEMs are now in
the process of testing and approving EALs for use in their
equipment. All of the major stern tube system manufacturers have approved at least one EAL. Many of the thruster
manufacturers have also approved EALs for new installations as well as equipment retrofitted with compatible seals.
Shear stability of EALs is important to protecting gears
LUBRICANT PERFORMANCE FACTORS
SHEAR STABILITY FACTORS
In general, a complete performance analysis of an EAL gear

oil or stern tube lubricant should include an assessment of
thermal, oxidative, and hydrolytic stability to estimate the
projected life of the oil under operating conditions. These
results can be compared to the initial purchase price of the
lubricant for a total cost of ownership value. Other measures
include its ability to protect the equipment from wear, scuffing, pitting, and corrosion. A high-performance lubricant
will extend equipment service life and reduce unplanned
downtime, thereby contributing to bottom-line profits.
Evaluation of lubricant viscosity is imperative to protect all
the components in a system. The kinematic viscosity of an
oil is affected by a number of factors. One inherent physical
property of a lubricant is its tendency to thicken in cooler
temperatures and thin at higher temperatures. This change
in viscosity as a function of temperature is called viscosity
index (VI). As a general rule, the higher the VI, the less the
oil is affected by temperature change.
When formulating a lubricant, viscosity improvers (which
are often polymer-based) can be used to increase the VI.
One measure of a lubricants protective value is its ability to

withstand shearing under pressure. Shear stability describes
a lubricants ability to resist a decrease in viscosity due to
exposure to mechanical loads. Maintaining the appropriate
and OEM-recommended viscosity is critically important to
both protect the equipment and to extend the time between
oil change intervals.
Lubricant thinning under stress is the result of the breakdown of viscosity modifiers. Under stress, viscosity modifiers
can either align at the molecular level and cause a temporary
loss of viscosity or they can break apart and cause a permanent loss in viscosity. Either scenario reduces their effectiveness in service. Increasing viscosity through the use of high
viscosity base stocks without the use or only moderate use
of viscosity modifiers tends to have better shear stability.
Viscosity modifiers are used in some EALs to push the viscosity of a low viscosity biodegradable oil to a higher viscosity
value. Using viscosity modifiers with a low viscosity base oil
to manufacture a lubricant can be more cost effective than
to use a high viscosity base stock.
However, a lubricant containing viscosity improvers may
not be as effective in high-shear, high-pressure, and extreme
temperatures. In these conditions, the oil can exhibit a
temporary loss of viscosity. When shearing continues or if
the forces are high enough, the polymers can break down,
eventually causing a permanent loss of viscosity.
LUBRICANT EFFECTS ON STERN TUBE

BEARINGS/SHAFT AND ON THRUSTERS
Stern tube systems and thrusters stress the lubricant due
to high loads, speed of rotation, and heat. In a stern tube
MARCH 2016
47
system, the weight of the propeller shaft and high thrust forces, combined with the speed of rotation and surface area, create significant
shear stress on the lubricant.
Of course, the function of a lubricant is to protect the components
it is lubricating, improve efficiency by reducing friction, and reduce
heat generation. However, to properly protect the components, an oil
relies on two main properties: viscosity and additives.
Determining proper viscosity is necessary to ensure a proper elastohydrodynamic (EHD) lubrication film. This film is essentially a
wedge of oil that builds up between two moving surfaces and provides
a separation. It is this separation that helps protect the surfaces from
wear, pitting, and scuffing. EHD film thickness is a function of speed,
pressure, surface condition, temperature, and viscosity.
A reduction in viscosity, either temporarily or permanently, will
reduce the lubricants ability to create a fluid film to separate the shaft
from the bearing. Thrusters operate under extreme loads as they transfer power generated by the vessels engines, through the bevel gears of
the z-drive, and on to the propeller. When the correct viscosity is not
maintained, an increase in micropitting and gear wear may occur. The
lubricant selected to protect shafts, bearings, and gears must be able to
withstand high shearing forces.
MAINTAINING OIL VISCOSITY TO PROTECT

AGAINST SHEARING
In practice, a good oil sampling program can be used to monitor the
condition of the oil. Tracking the viscosity over time will detect loss of
viscosity due to shearing.
Thats why monitoring trending data is part of a successful oil analysis program. The condition of oil should always be checked against a
representative baseline. A baseline can be established by directly sampling the sump soon after filling with a fresh oil and after a short duration of operation. The frequency of sampling is typically established by
the OEM, or depending on the application and operating conditions,
an appropriate schedule of resampling can be established. An adequate
interval is typically based on the number of service hours or at set
intervals to check for viscosity stability. If one of the tested parameters
ever falls out of the OEM-recommended range for the equipment, it
should be replaced and a new baseline should be established.
While an oil analysis program will help accurately measure how the
current oil is performing, there are numerous tests that a manufacturer
can perform in the lab to characterize the oil performance to help the
OEM or end user make an informed purchasing decision prior to filling
the system or gearbox.
A preferred method is the standard test method CEC L-45-A-99,
also known as the KRL tapered roller bearing test. Used by OEMs
and lubricant manufacturers, this test simulates lubricant performance
under shear stress in actual gear and bearing applications. It is considered the most severe of the available shear stability tests and offers
the best correlation to actual field performance. The CEC L-45-A-99
test simulates a high shear condition to accelerate the breakdown of oil
viscosity. To accomplish this, tapered roller bearings are used because
the large surface area of the roller exposes the oil to a high percentage
of shear. The test bearings are run at 1,450 rpms for 20 or 100 hours
under a load equal to 5,000 N, at 60C. The results are calculated by
measuring the percentage of viscosity change between the oil viscosity
pretest and the oil viscosity post test. A small value indicates a high
shear stability, while a high value indicates poor shear stability.
Figure 1: EAL CEC L-45-A-99 test results
RESULTS OF TESTING SHEAR STABILITY

Internal testing of various EALs using the test method CEC
L-45-A-99 has produced a wide range of results among the sample
lubricants. Synthetic ester-based products that did not use viscosity
modifiers produced the best results. Even after a short test duration
of 100 hours, two of the samples with viscosity modifiers showed
a minimum of 50-percent loss in viscosity.
However, the two oils that were formulated without viscosity improvers maintained a consistent viscosity. Even a small drop in viscosity can
drop the ISO viscosity grade down into the next VI category permanently. Running too light of an oil viscosity can reduce the lubricants
ability to provide a sufficient oil film. If this occurs, lubricant protection is compromised, which leads to a higher probability of premature
wear, scuffing, and pitting.
CONCLUSION
EALs are formulated to protect the environment, but there is no
need to select an EAL that compromises the protection of thrusters
or propeller shaft bearings.
Careful selection of EALs is necessary to prevent failures of bearings
and gears. Protecting against shearing stresses is achieved by selecting
EALs with a high VI. But lubricants that employ viscosity modifiers
to raise VI can compromise shear stability. Selecting an EAL using a
base oil with an inherently high VI assisted by a good oil sampling
program will ensure the high level of shear protection that meets
todays environmental and equipment requirements.
ABOUT THE AUTHORS: Ben Bryant joined Klber Lubrication NA LP in 2011 as the marine market manager responsible for developing new business in the
marine industry. Bryant is a graduate of the Massachusetts Maritime Academy and holds a 1,600-ton Masters license with experience on oil tankers, offshore
supply vessels, and tug and barge units. In 2009, he earned a Master of Marine Policy from the University of Rhode Island, and he holds a masters in business
administration from Boston College. Bryants primary focus at Klber Lubrication is to launch its new portfolio of environmentally acceptable lubricants for the
marine industry. He has authored articles explaining the proposed lubricant standards established in the 2013 Vessel General Permit. He can be reached at ben.
bryant@us.kluber.com.
Craig Desrochers, P.E., is an application and service engineer at Klber Lubrication NA LP. He obtained his professional engineering license in 2013. His
primary focus at Klber Lubrication is application engineering, managing the gear oil product line, and working with OEMs. Desrochers holds a bachelors
in mechanical engineering from Western New England University. He is an active AGMA member and has a continued focus on the gear oil industry.
48
gearsolutions.com
NOW REPRESENTING
GERMAN MACHINE
TOOLS OF AMERICA (GMTA)
is now the authorized North
American representative for
Rasoma, a builder since 1919
of high-quality vertical turning
centers, 4-axis shaft turning
centers, end machining centers,
double-spindle machining centers
and a variety of automated
solutions for the automotive
and other industries.
The addition of Rasoma to
our other lines makes GMTA
a viable partner for nearly every
application in the powertrain,
gearmaking, bearing and other
production line concepts for auto,
motorcycle and off-road vehicles,
as we bring full application
engineering, machine building,
laser integration and commissioning
to your facility, with single-source
support and service from our plants
in Ann Arbor, Michigan and
Queretaro, Mexico.
Take a look at Rasoma and all our
lines at www.gmtamerica.com.
Youll be glad you did.
Call Scott Knoy

today for all the details.
734-973-7800
German Machine Tools of America
Ann Arbor, Michigan | Queretaro, Mexico | www.gmtamerica.com | Email: company@gmtamerica.com
MARCH 2016
49
Nanodynamic coating facility
50
gearsolutions.com
An Update on Broaching
Technology
By Dwight Smith
Advances in both broach tools and broach machines have progressed the state
of the art in broaching.
THE WORLD OF BROACHING HAS CERTAINLY
changed since the 1850s when it emerged as a viable
production metalworking process. Advancements have
been made in machine technology, processes to increase
performance, and specialty coatings to improve tool life.
BROACH TOOL ADVANCES

Most manufacturers seek higher productivity and lower
costs as ways to improve profitability. The cutting tool
industry is constantly being challenged to improve tool
life and re-sharpening accuracy.
A recent advancement in broach tools is the use of specialty coatings. By applying the super-hard Nanodynamic
coating, broach tools are being produced with finer
surface finish. This improved surface finish, along with
the hardness of the coating, can produce better tool life.
The broach tool surface finish is significantly improved
over an uncoated or TiN-coated tool as shown in Table 1.
Nanodynamic
TiN coated
Uncoated
Ra 0.03mm
0.04mm
0.33mm
Table 1
Testing has revealed superior edge retention and tool

life in real-world broaching applications. It has been
observed that workpiece flaking is reduced and burr
sizes are one-seventh the size created by conventional
broach tools.
In broaching, it is edge wear that ultimately governs
tool life as well as the number of pieces that are cut before
sharpening is needed. Real-life performance has shown
that Nanodynamic coating greatly delays the onset of
edge wear, thus extending the working life of the tool.
Table 2 is a comparison of edge wear measurements both
with and without Nanodynamic coating. It shows that the
wear on the coated tool at 10,000 pieces is the same as the
uncoated tool at 5,000 pieces. This represents twice the
number of parts. If the obtuse edge wear of .101 mm produced parts in tolerance, then the tool could produce three
times the number of parts compared to an uncoated tool.
HARD BROACHING
Continuous improvements in automotive powertrain
applications have driven most gear manufacturing to
hard finishing operations to ameliorate the effects of heat
treat distortion. Gear grinding and honing are utilized
for nearly new transmission projects. Analogous to this is
the use of hard broaching to improve part geometry after
heat treatment. This need is being met on internal spline
applications by the use of hard broaching.
After a green (preheat treatment) broaching process,
the components are typically carburized and hardened to
a hardness of Rc 58-62. Cutting speeds generally range
from 60 to 63 meters per minute. Two methods of hard
broaching are considered for each application. If the
removal of distortion is the only goal, and no cleanup is
acceptable, then the part can be broached to the finished
size and then heat treated. After heat treatment, the hardened parts can be hard broached again, to the finished
nominal size. This will remove only the material that was
displaced by the heat treatment distortion.
The other method, defined stock removal, requires
that the green broach be designed to leave enough stock
to ensure full cleanup at the afterheat treatment hardbroaching process. A specially designed broach tool
is then used to broach the hardened parts, removing
approximately .100 mm (.004 inch) of stock per flank.
The results can be compared to a ground component at
a much lower per-piece cost.
Other advantages of hard broaching include better
process capability compared to the capability that can
be achieved with parts that are only green broached
and then heat treated. The critical characteristics, such
as dimension between pins and circularity, are greatly
improved because the part is broached to the desired
condition, which removes the distortion caused by heat
treatment. Care must be taken to produce the part in
the green condition with sufficient stock to be removed
by the hard-broaching process if full cleanup is required.
Hard broaching is applicable for components that
require precise concentricity, for example, internal splines.
Broach tool data:

Body: 125 cutting teeth, two starts, length 2,286 mm, material: PM-M4
Shell: 18 cutting teeth, four starts, length 254 mm, material: PM-M4
Uncoated
Nanodynamic Coated
Pieces cut
5,000
5,000
10,000
15,000
Acute Edge Wear (mm)
0.050
0.050
0.076
0.076
Obtuse Edge Wear (mm)
0.076
0.050
0.076
0.101
Table 2
MARCH 2016
51
This process also improves the spline bearing area, thus improving
and strengthening the interface between shaft and gear. Where automatic assembly operations take place, the improvement in process
capability and reduction of variation is a considerable benefit.
MAINTENANCE AND SHARPENING

Broach tool maintenance consists primarily of sharpening the cutting edges by grinding. This is similar to the original manufacturing
process and needs to be accurate. To ensure accurate and repeatable
results, the use of CNC broach grinding machines is a practical
necessity. With proper grinding, broach tool maintenance also
requires stripping and recoating the coating, whether it is TiN or
the aforementioned Nanodynamic advanced coating.
MACHINE ADVANCES
A major advancement is the development of electromechanical
broaching machines. This allows the elimination of large and inefficient hydraulic systems. The use of these machines for production
of helical internal gears for automotive use has almost completely
replaced gear shaping.
This technology has been developed and implemented in electromechanical rising table broach machines, electromechanical
pot broaching machines, and electromechanical horizontal surface
broaching machines.
Electromechanical rising table broach machines can exert up to
60 tons of force to produce helical or spur internal ring gears. Close
attention is paid to the design and construction of the machines to
eliminate any deflection or movement of the machine during the
powerful cutting stroke.
Although the standard machines need an overhead clearance of
7 meters (23 feet), a costly pit of reinforced concrete is no longer
needed. A compact version, BH50-17, needs only 5 meters (16.4 feet)
of ceiling clearance. For high production, two broach tools and part
fixtures are used to make two parts with each cycle of the machine.
With a typical cycle time of approximately 22 seconds, two parts
are produced for a floor-to-floor time of 11 seconds. It would take
a large fleet of gear shapers to match this productivity. Many new
planetary transmissions have been specifically designed to allow for
broaching the internal ring gear rather than shaping.
Electromechanical rising table broach machine
CNC axis controls the rotation of the tools during the broaching
stroke, creating the exact helix needed. Minute adjustments are also
possible, and changing from one helix to another is accomplished via
the CNC program without requiring mechanical changes.
Second, electromechanical systems use energy only when needed
to produce the part. In contrast, a hydraulic system generally needs
to run a large pump continuously, which uses prodigious amounts
of electricity and creates noise and thermal pollution. Also, hydraulic
systems are notorious for developing leaks and needing repairs and
maintenance.
Finally, the constant torque of the electromechanical drives produces a smoother cutting action. This can produce more consistent
part quality and better surface finish on the parts and can improve
tool life.
When external, non-helical forms are required, electromechanical
pot broaching machines are utilized. External splines, cams, and other
shapes are created. The tool is made up of a series of rings with a
series of form inserts that sequentially and progressively cut the desired
shape into the outside of the part blank. The main advantage of this
type of machining is the productivity where cutting speeds of up to
9.13 meters per minute are used. Because of the electromechanical
design, the return speed is over 18 meters per minute, minimizing
cycle times even further. Typical cycle times are from 12 to 30 seconds
Advantages of an Electromechanical System over the Previously with up to 50 tons of force available. Parts are produced with high
accuracy and excellent surface finish.
Used Hydraulic Machines
First, control and flexibility are greatly improved. By using the
CNC control to monitor and adjust the broaching cycle, optimum CONCLUSION
cutting speeds can be achieved for each individual part, material, Although the broaching process dates back several generations, it is
and situation.
still a viable method for high-volume production. With the advanceIn traditional hydraulic systems for helical broaching, the broach ments in machine technology, such as the electromechanical systems,
machine requires a specific helical guide (lead bar) to rotate the tool this metal removal process can produce quality internal forms such
during the machining stroke. In some cases, the part and fixture as gears and splines faster and more economically.
are rotated in concert with the cutting stroke. The guides are highly
With the advent of Nanodynamic coating, broaching efficiency is
precise, add typically long (and costly) lead items, and can be used further enhanced. The per-piece cost of consumable tooling can be cut
only for one specific helix, therefore, changing the guides is a lengthy by half and perhaps even two-thirds. Utilizing a constant-force tool
procedure and prohibits flexibility.
design improves tool life and can result in a shorter tool. Combining
The advent of electromechanical broach machines allows helical the advancements in broach tools with fast and rigid electromechanibroaching without the need for the specific mechanical guides. A cal machines, broaching is still advantageous to the industry.
ABOUT THE AUTHOR: Dwight Smith at Federal Broach and Machine Company has more than 25 years of experience in the gear manufacturing
industry, including metrology, analysis, and project management. Smith serves as a committee chairman for AGMA, and he is an instructor for the
AGMA Basic Gear School.
52
gearsolutions.com
PRODUCT
SHOWCASE
NEW PRODUCTS, TRENDS,

SERVICES, AND DEVELOPMENTS
RASOMA MACHINE TOOLS NOW AVAILABLE IN NORTH AMERICA FROM GMTA

Provided by German Machine Tools of America (GMTA), Rasoma
machining centers, used primarily for gear-making, are now offered to
the GMTA customer base in automotive powertrain, off-highway, and
other high-performance markets. The full line of Rasoma machining
centers includes vertical turning centers, 4-axis shaft turning centers,
end machining, double spindle, and various special purpose machining centers with full automation.
Founded in 1919 and based in Dbeln, Germany, Rasoma is a
large machine tool builder that provides contract manufacturing to
some of the best-known brands in the global auto industry, as well
as its own brands.
Gear machines for milling, hobbing, and shaping are available in
a variety of configurations, and the GMTA application engineering
team can assist interested parties to determine the best solution.
Rasoma machining centers offer high rigidity due to separate X
and Z slides, and the machine head is designed as a monoblock with
polymer concrete fill. Thermal stability is enhanced by cooled motor
spindles, and the rapid traverse on these centers ranges up to 60 m/
min. at high acceleration, with feed and removal speeds up to 120
m/min., less than six seconds from part to part and turret indexing
typically under one second.
Full option packages include robotic handling and part articulation, integrated metrology onboard, working inside or outside the
work envelope, full tool measurement and monitoring systems, and
driven tool packages, all controlled by a single Siemens CNC.
This alignment dovetails perfectly with our other lines of gearmaking, laser and finishing machines, and systems, said GMTA
President Walter Friedrich. It will enhance our value proposition
considerably in our current market of primary automotive and will
also open other market opportunities for our company. We have made
substantial investments in new personnel and floor space, both here in
the U.S. and at our Mexican facility, to support these new additions
to our portfolio of quality German machine tools.
Videos of Rasoma machines are available on GMTAs website.
gmtamerica.com
EXPANDED CONTOUR MACHINING CYCLE FOR SINUMERIK CNCS FACILITATES

4-AXIS TURNING
The expanded contour machining cycle for Siemens Sinumerik CNC
controls now facilitates 4-axis turning on lathes. Two turning tools,
opposite one another, machine the workpiece simultaneously, enabling
the machining time to be significantly reduced. In addition, the two
turning tools, opposite one another, prevent workpiece distortion,
significantly improving dimensional accuracy particularly on long,
thin workpieces.
A unique advantage of the Siemens controls is that the new machining process can be programmed directly on the Sinumerik CNC without a CAD/CAM system. With just two additional parameters, the
user expands the machining process for a tool into highly productive
balanced cutting with two tools. The Sinumerik contour machining
cycle automatically creates the CNC sequences.
In 4-axis machining, a distinction is made between synchronous and
asynchronous path control with the channel-based Sinumerik control
executing two independent CNC programs simultaneously.
In synchronous machining, which is particularly suited for roughing
and finishing, the cutting inserts are exactly opposite one another and
move identically. The cutting depth is equally distributed over both
cutting edges, making it possible to double the feed rate per revolution
and chip volume. In asynchronous path control, used for roughing,
the two tools move differently.
In longitudinal turning, the cutting inserts work at different diameters, and in face turning, they work at different Z positions. The
chip volume relative to a tool can be roughly doubled due to the short
waiting times for tool synchronization.
siemens.com
MARCH 2016
53
KLBER LUBRICATIONINTRODUCES HIGH-TEMPERATURE

OIL FOR SLIDING CHAIN SYSTEMS
Klber Lubrication, a worldwide manufacturer of specialty lubricants,
recently introduced Klbersynth CHZ 2-225, a fully synthetic hightemperature oil developed for sliding chain systems in biaxial highspeed film stenters where oven temperatures may be higher than 200C.
The use of Klbersynth CHZ 2-225 can extend maintenance
intervals and reduce the cost of maintenance operations. This special chain oil offers an ideal solution for the continuous operation
of film stenters. Machine uptime and energy costs are important
considerations for film stenter operators in order to secure profitable
production, and as a result, chain oil selection is critical. Residue
buildup can prevent penetration of a lubricant to the critical friction points, including the chain pins and the guide rails. This may
lead to higher friction and requiring more lubricant, which
could in turn lead to further contamination, making
premature cleaning of the whole machine necessary a costly and

time-consuming procedure. Downtime is inevitable, leading to less
machine availability.
Klbersynth CHZ 2-225 is composed of an ester-base oil containing
special additives to reduce the adhesion of residues in the chain system.
As a result, the friction points can be supplied with sufficient lubricant
for many months or even years. Premature cleaning is no longer necessary, and intervals between residue-induced maintenance operations
increases. The oil can also cope with long-term operation at high speeds.
Klbersynth CHZ 2-225 offers film stenter operators a costeffective lubricant that provides optimum performance with higher
machine time availability, resulting in increased profitability.
klubersolutions.com
SCHUNK ANNOUNCES NEW TOOLHOLDER FOR DEMANDING

PRECISION MACHINING
Schunk is expanding its program for high-performance hydraulic expansion toolholders with the Tendo Aviation.
This toolholder specifically focuses on demanding applications, which usually occur in the aerospace industry.
Tendo Aviation combines the strength of hydraulic expansion technology with that of Weldon toolholders.
This includes high runout accuracy, a balancing grade of G 2.5 at 25,000 min-1, perfect vibration damping,
NEW!
Two More Services from

the Experts at Federal Broach
FULL SERVICE
GEAR TOOL
MAINTENANCE
PRODUCTION
BROACHING
SERVICE
Hob, Shaper, Shave Tool,

Broach Sharpening
& Recoating
Prototype, Short Run

or Full Production
Broaching Machines & Gear Cutting Tool Experts

1961 Sullivan Drive
Harrison, MI 48625
989-539-7420
www.federalbroach.com
54
gearsolutions.com
and a fast tool change using an Allen key. An

integrated anti-pullout mechanism ensures an
orientation of the tool and form-fit clamping
when using the Weldon shank. The mechanism prevents tool pullout, and positional
tolerances can be held. These features allow
the full potential of both tool and machine
to be used.
Tendo Aviation allows maximum torque
transmission at consistently high precision
and process reliability. There are tremendous advantages compared to conventional
Weldon and Heat Shrink toolholders, where
the runout accuracy decreases over time. The
runout accuracy and vibration damping of
the Tendo hydraulic toolholders prevents the
cutting edge from wear, extends tool life, and
ensures smooth surfaces. The uniform load
profile ensures a longer service life of spindle
and spindle bearing.
This affordable toolholder is available for
the interfaces HSK-A63, HSKA 100, CAT
40, and CAT 50.
bar. Retention knobs are sold separately so each

type of machine can be properly fitted. The
bars are supplied in protective wooden boxes
with handles, hinges, and clasps.
Brineys expanded test bar offering
includes CAT 40 and CAT 50 models; BT30,
BT40, and BT50 models; and HSK50A,
HSK63A, HSK80A, and HSK100A models.
Special test bar designs are also available
from Brineys special design team that works
daily with customers to design and build
special tools.
brineytooling.com
Generate Undeniable
Momentum
schunk.com
BRINEY TOOLING
SYSTEMS EXPANDS
PRECISION TEST BAR
OFFERING
Excessive tool wear and tool breakage on
machine tools is primarily caused by spindle
runout. For every .0001-inch of total indicator runout (TIR) that can be reduced, tool
life can be increased as much as 10 percent.
Thats why regular inspection of the machine
tool spindle with a precision test bar for accuracy and alignment is imperative to ensure
consistent quality production.
Briney Tooling Systems has been a leading supplier of precision test bars for over
25 years and has continued to expand their
CAT, BT, and HSK offerings as spindle
designs have evolved. The test bar is easy to
use and is the quickest way to confirm that
the machine spindle is running accurately.
For example, if there has been a machine
crash for any reason, it is essential that a test
bar be used to ensure proper realignment of
the spindle.
Each Briney test bar is provided with a
certificate of accuracy that spells out the bar
diameter and gage length that is inspected
and certified to four decimal places. That data
accompanies each test bar and is etched on the
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MACHINERY
FEATURED SUPPLIERS
Gibbs Machinery Company REF #102
Phone: 586-755-5353 Fax: 586-755-0304
Email: rj@gibbsmachinery.com
Website: www.gibbsmachinery.com
Havlik International Machinery, Inc. REF #103
Phone: 519-624-2100 Fax: 519-624-6994
Email: havlik@bellnet.ca
Website: www.havlikinternational.com
Midwest Gear Corporation REF #104
Phone: 330-425-4419 Fax: 330-425-8600
Email: sales@mwgear.com
Website: www.mwgear.com
New England Gear REF #105
Phone: 860-223-7778 Fax: 860-223-7776
Email: jeff@newenglandgear.com
Website: www.newenglandgear.com
R. P. Machine Enterprises, Inc. REF #106
Phone: 704-872-8888 Fax: 704-872-5777
Email: sales@rpmachine.com
Website: www.rpmachine.com
GEAR ACCESSORIES, PARTS & TOOLING

FELLOWS Model #10-4/10-2, All Parts Available REF#105
Tilt Tables for 10-2/10-4, Qty 2 REF#105
FELLOWS Parts Available For All Models REF#106
BARBER-COLMAN PARTS AVAILABLE FOR ALL MODELS REF#106
G&E PARTS AVAILABLE FOR ALL MODELS REF#106
GEAR HOBBERS/CUTTERS CNC

PFAUTER #PE-150, 6-Axis CNC, 6 Dia, 5 DP, 6 Face, Fanuc 18MI REF#106
G&E #60 S-2 CNC Gasher/Hobber REF#106
BARBER-COLMAN #16-36, 16 Dia, 4-Axis, 6 DP, 36 Face REF#106
MUIR CNC Gear Hobber, 4-Axis, 118 Dia REF#106
LIEBHERR #L-252 3-Axis, 9.8 Dia, recontrolled 2008 REF#106
LIEBHERR #ET-1802 CNC 98 Dia Internal, 3-Axis REF#106
G&E #120GH, CNC, Gasher/Hobber, Twin Stanchion, 1/2 DP, 42 Face, 94 REF#106
PFAUTER P400H, 5-Axis, 18 Dia, 1 DP, Recontrolled 03 REF#106
G&E #96GH, CNC, Gasher/Hobber, New 09 REF#106
PFAUTER PE 300 AW CNC 6-Axis REF#106
Pfauter PE150, 15MB Fanuc, Chip Conveyor, Auto Load REF#102
Pfauter PE150, Siemens 3M, Magnetic Chip Conveyor, Oil Chiller REF#102
Pfauter PE150, Fanuc 15, with light hob slide 8 REF#102
Pfauter PE80, 15MB Control, Auto Load, Light Curtain REF#102
Liebherr LC82 15M Fanuc Control, Auto Load REF#102
Liebherr LC502, 20, Fanuc 16im, 2007 REF#102
Liebherr LC380, 440mm W/100mm Hob, 2008 REF#102
GEAR HOBBERS/CUTTERS
TOS OFA Series Conventional Gear Hobbers, 12 & 40 Dia REF#103
TOS OHA Series Conventional Gear Shapers, 12 & 40 Dia REF#103
PFAUTER P1251 Hobbers s/n 25-276 and 25-277 REF#105
PFAUTER (1) RS-00 s/n 17593 REF#105
BARBER COLEMAN (1) 16-36 multi cycle s/n 4404 REF#105
BARBER-COLMAN #16-16, Multi-Cycle, Dual Thread Worm and/or Single Thread
Worm REF#106
G&E #48H 48 Dia, 18 Face 2 DP, Universal REF#106
G&E #48H, 48 Dia, 35 Face, 3 DP, Gooseneck Attachment REF#106
BARBER-COLMAN #6-16, 6 Multi-Cycle REF#106
G&E #36H Differential, Excellent Condition REF#106
BARBER-COLMAN #14-30, 14 Dia, 30 Face, 3.5DP REF#106
BARBER-COLMAN #14-15, 14 Dia, 15 Face, 1 to 4 Start Worm, Several REF#106
BARBER-COLMAN #16-16, 16 Dia, 16 Face, 6DP REF#106
BARBER-COLMAN #16-36, 24 Dia, C-Frame Style, 4 1/8 Bore REF#106
BARBER-COLMAN #16-56, 16 Dia, 56 Face, Differential REF#106
G&E #24H Universal Head, Infeed, Tailstock, Differential, 50s REF#106
LIEBHERR #L-650, 26" Dia Cap, 14.5" Face, 2.5 DP, New 70s REF#106
56
gearsolutions.com
CONTACT GEAR SOLUTIONS AT

800-366-2185 TO LIST YOUR MACHINERY.
G&E #16H Gear Hobber, 16"Dia REF#106

BARBER-COLMAN #6-10, 6 Dia, 10 Face, 16 DP REF#106
KOEPFER #140 , 2.75 DIa, 4 Face REF#106
LANSING #GH-50, 50 Dia, 17.75 Face, 2 DP REF#106
LIEBHERR #L-252, 9.8 Dia, 7.9 Face, 4.2 DP REF#106
BARBER-COLMAN TYPE T REF#106
G&E #36HS 36Dia, 14 Face 3 DP REF#106
PFAUTER #P-3000, 120 Dia, Single Index REF#106
SCHIESS RFW-10-S 55 Dia REF#106
SCHIESS 1 RF-10, Dia 60 150 L, .50 DP REF#106
G&E #40TWG, 48 Dia, 18 Face, 3 DP REF#106
G&E #60S, 72 Dia, 14 Face, 1.25 DP REF#106
G&E #72H, 72 Dia, 24 Face, 1 DP REF#106
G&E #96H, 104 Dia, .50 Face, 1.25 DP REF#106
PFAUTER #P-630, 25 Dia REF#106
PFAUTER P250 10 Dia REF#106
GE/Fitchburg Hobber 32 Dia, 72 Face 1.25DP REF#106
JF Reinecker 40 Dia 35 Face REF#106
LIEBHERR L-160-R 6.5 Dia REF#106
MIKRON #102.04 , 4 Dia, 5 Face REF#106
PFAUTER P-900 36 Dia REF#106
BARBER-COLMAN #25-15 25 Dia, 15 Face, 2.5 DP REF#106
PFAUTER #P-630R, 25" Max. Spur Dia, 12" Max Rotor Dia. 12" REF#106
Lees Bradner 7VH, 8PD, 10 Face, , Magnetic Chip Conveyor , Hob Shift REF#102
Lees Bradner 7VH, 8PD, 4PD, Magnetic Chip Conveyor, Hob Shift REF#102
Barber C. 16-15, 4 Hob, Crowning, Differential, Double Cut, 3 DP, 1977 REF#102
G & E 36H, 36, Hi-Column, Differential, From AEM Toolroom, Excellent REF#102
G & E Model 48HS, 48PD, 18 Face, 2.5 DP, Hi-Column, Heavy Duty, 8 Hob REF#102
Liebherr L301, 12 Crowning, Double Cut, Differential, Hob Shift REF#102
Liebherr L401, 16, Differential, 2-Cut Cycle, Chip Conveyor, 7.566 Hob Dia. REF#102
Liebherr L402, 2-Cut, Infeed, Differential, Tangential Feed, 19.3 OD W/4 Hob REF#102
Cleveland 1886, Hi-Helix, Hob Head, Auto Hob Shift, 4-Pitch, 1975 REF#102
GEAR PINION HOBBERS & SPLINE MILLERS

HURTH #KF-32A 15 Dia, 59 Face, 67 REF#106
GE/Fitchuburg Pinion Hob 32 Dia, 72 Face REF#106
MICHIGAN Tool #3237 REF#106
FITCHBURG Pinion Hobber 42 Dia, 72 Dia REF#106
GEAR HOB & CUTTER SHARPENERS (INCL CNC)

TOS OHA Series CNC Gear Shapers, 12 & 40 Diameter REF#103
TOS OFA Series CNC Gear Hobbers, 12 & 40 Diameter REF#103
BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, 57 REF#106
FELLOWS #6SB, Helical Cutter Sharpener, 6 Dia, up to 50 Degrees REF#106
KAPP #AS-305GT, 1 DP, 28" Grind Length, 10" Diam., Str. & Spiral REF#106
KAPP #AS204GT, 10 Dia, Wet Grinding, CBN Wheels, 82 REF#106
REDRING MODEL #SGH "PREIFORwM" SHAVE CUTTER GRINDER/SHARPENER REF#106
STAR 6X8 HOB SHARPENER PRECISION GEAR & SPLINE HOBBER REF#106
BARBER-COLMAN 2-2 1/2 , 2.5 Dia REF#106
KAPP #AST-305B, 27.5 Dia, REF#106
KAPP AS-410B REF#106
GLEASON #12 Sharpener, 3-18 Cone REF#106
Red Ring Shaving Cutter sharpener Periform REF#106
Star #6 Gear Cutter Sharpener REF#106
Star 4HS Hob sharpener REF#106
Star HHS Horizontal Hob Sharpener CNC, Max Dia 10 Max length 12 New 1990 REF#106
Barber Colman 10-12, Water Guards, Dresser, Index Plates REF#102
Star 2VHS, 6x6, Coolant, Change Gears, REF#102
Star 4 x 4 (G691), 0-7000 Spindle Speeds, Auto Cycle, Coolant REF#102
Barber Colman 4-4, Index Plates, Very Light Use, Excellent REF#102
Gleason 538, 18 Shaper Blades, Makes Blades from Blanks, Light Use, Extras REF#102
Star 2VHS, 6 x 6, Coolant, Change Gears REF#102
GEAR SHAPERS CNC

36 Shapers, 14 Throat Risers, 53 of Swing, Qty 3 REF#105
FELLOWS #10-4/10-2, Qty 150 REF#105
HYDROSTROKE #50-8, Qty 2 REF#105
HYDROSTROKE #20-8, Qty 5 REF#105
HYDROSTROKE #FS630-125, Qty 1 REF#105
HYDROSTROKE #FS400-90, Qty 2 REF#105
FELLOWS #20-4, Qty 6 REF#105
FELLOWS #48-8Z, Qty 1 REF#105
FELLOWS #FS-180, 3-5 Axis, 7 Dia, 1.25 Face., 6 DP, New 88 REF#106
LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#106
LORENZ # LS-180, 4-Axis CNC, 11 OD, 2 Stroke, 5 DP REF#106
LORENZ #LS-304 CNC Gear Shaper 5-Axis Heckler & Koch Control REF#106
FELLOWS FS400-125, 16 Dia, 3.5 DP 5 Face REF#106
FELLOWS #10-4 3-Axis (A/B), 10" Dia, 4" Face, 4 DP New .09 REF#106
FELLOWS #10-4 2-Axis, 10 Dia 4 Face REF#106

FELLOWS #20-4 3-Axis 10 Dia, 4 Face REF#106
FELLOWS FS400-90 Hydro-stroke Gear Shaper CNC Nominal Pitch 15.7" REF#106
Fellows 20-8, CNC Gear Shaper, Remanufactured and recontrolled REF#106
Fellows Model Z gear Shaper REF#106
Lorenz SN4 Gear Shaper, Max OD 7, 2 Face, Max 6 DP with Loader REF#106
RP/ Stanko 48-8 Remanufactured Gear Shaper, Fanuc 3 Axis, 18i M Control, new
2010 REF#106
GEAR HOBBERS
Barber Colman Model 4-4HRS, Hob Sharpener 4 Max OD, 4 Length REF#106
Fellows FH 200 Gear hobber, universal hobbing Machine REF#106
Barber Colman 6-10, CNC, CRt 5 Axis, 6 Dia, 10.5 travel, 6 DP REF#106
Barber Colman Hobber Type T REF#106
Barber Colman model #14-15 Gear Hobber, horizontal Heavy Duty REF#106
Barber Colman Model #16-36 GearHobber REF#106
Barber Colman Model #16-56, 16 dia, 56 Face, adj. Air Tailstock REF#106
Barber Colman Model 2.5-2 gear hobber, 2 length Manual Dresser REF#106
G&E Model 5.2 CNC Internal Gear gashing head REF#106
Jeil JDH-3, Gear hobber, Max Dia 31.5, 3DP, 22.8 Table Diameter REF#106
Jeil JDP-2, Gear hobber, Max Dia 26, 4 DP, 19.5 Table Dia, Differential
and tailstock REF#106
Liebherr ET 1802, Internal Gashing head, Fanuc 16i Control, 98Max dist 17 Face REF#106
Liebherr L-402 Gear hobbing Machine, New 1977 REF#106
Liebherr LC 752, 6 Axis CNC Hobber, Max OD 29.5, Max Face width 23.6 REF#106
Micron Model 120.01 w/bevel Cutting Attachment, New 1975, 1.6 dia, 25.4 DP REF#106
Nihon Kakai Model NTM-3000, Spline Hobbing Machine, Max dia 400mm, 3150mm between
Center REF#106
Pfauter P900 Reman and Recontrolled, Max OD 120 REF#106
Pfauter Model PE125 CNC Gear hobber REF#106
Pfauter model PE300 CNC, Max OD 12, Max gear face 15, 3 DP, 6 Axis REF#106
Reinecker Heavy Duty Gear Hobber REF#106
Scheiss Model RF10 Horizontal Hobber, 60 dia, 144 face, 180cc, 8 DP REF#106
GEAR SHAPERS
FELLOWS #10-2, (10 Dia), 2 Face REF#105
FELLOWS #10-4, (10 Dia), 4 Face REF#105
FELLOWS (200) 10-4 / 10-2 Shapers REF#105
FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/ 6 axis 16iMB Fanuc (2009) REF#105
FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/ 6 axis 16iMB Fanuc (2009 REF#105
FELLOWS (1) #7 125A Face Gear Machine REF#105
FELLOWS (2) #3 Face Gear Machine REF#105
(1) 4ags with adjustable Helical Guide s/n 30634 REF#105
(1) #7 125A adjustable Helical Guide REF#105
FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc Controller (2009) REF#105
FELLOWS (2) Swing-away center support for 10-2 / 10-4 REF#105
FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/ 6 axis 16iMB Fanuc
(2009) REF#105
FELLOWS (2) FS400-170 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#105
FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#105
FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis 21i Fanuc Controller (2009) REF#105
FELLOWS (1) 48-8Z Shaper w/ 14 throated riser (53 of swing) REF#105
FELLOWS (1) Horizontal Z Shaper s/n 21261 REF#105
FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB 4 axis Fanuc controller
s/n 34326 REF#105
FELLOWS (1) 36-10 Gear Shaper REF#105
FELLOWS (1) 10x6 Horizontal Z Shaper REF#105
FELLOWS (1) 36-6 Gear Shaper w/ 13 riser s/n 27364 REF#105
FELLOWS (1) 10-4 Shaper w/ 3 riser w/ 4 axis 21i Fanuc Controller (2009) REF#105
All Parts for 10-4/10-2 Fellows Gear Shapers REF#105
FELLOWS #36-8, 36 Dia, 8 Face REF#106
FELLOWS #100-8 100 Dia, 8 Face REF#106
FELLOWS #612A, 615A, #645A REF#106
FELLOWS #10-4, 10 Dia, 4 Face, 4 DP REF#106
FELLOWS #4A Versa, 10 Dia, 3 Face, 4 DP, New 70s REF#106
FELLOWS #10-2, 10 Dia, 4 Face, 4 DP REF#106
FELLOWS #20-4, 20 Dia, 4 Face, 4 DP, 70s REF#106
FELLOWS #3-1,/3GS, 3 Max Dia, 1 Face, Pinion Supp, High Precision REF#106
FELLOWS #48-6 INTERNAL GEAR SHAPER ONLY,0-72"OD,6" Face REF#106
MAAG #SH-150, 57" Dia.12.6" Face REF#106
PFAUTER #SH-180 Shobber 7" capacity hobbing, 9.45" cap REF#106
FELLOWS #36-6 Max Dia 36 6 Face, 3 DP REF#106
FELLOWS #HORZ Z SHAPER, 10 x 6 Dia 27.6 Face 8.5 REF#106
FELLOWS #4GS & 4AGS, 6 Dia, 2 Face, 4DP, 68, Ref.# Several REF#106
FELLOWS #624A, 18 Max Dia, 5 Face REF#106
FELLOWS #7, #7A, #715,# 75A, #715, #725A, 7 Dia, 0-12 Risers, Several Avail REF#106
MICHIGAN #18106 SHEAR-SPEED GEAR SHAPER,14" Dia, 6"Face REF#106
FELLOWS Model Z Shaper, 5" Stroke, 50s REF#106
STAEHELY SHS-605, Gear Shaper REF#106
FELLOWS #6, #6A, #61S, From 18-35 Dia, 0-12 Risers REF#106
FELLOWS #8AGS Vertical Gear Shaper, 8 Dia, 2 Face, 6-7 DP REF#106
TOS OHA50 CNC 5 20 Dia 5 Face REF#103
Mitsubishi SC40, 400mm-15.7, 18iMB Fanuc, 2005 REF#102
Fellows FS180, 7, Hydrostatic Guide, 15M Fanuc, Manual Pulse Generator REF#102
Fellows 10-2, Fanuc Control, LR Mate 100 Robot W/Independent Control REF#102
GEAR DEBURRING/CHAMFERING/POINTING
CROSS #50 Gear Tooth Chamferer, 18 Dia, Single Spindle REF#106
REDIN #20D, 20 Dia, Twin Spindle, Deburrer/Chamfer REF#106
SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14 Dia, 5 Face, 82 REF#106
SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10 Max Dia, (3) New 96 REF#106
REDIN #24 CNC Dia 4 Setup Gear Deburring REF#106
CROSS #60 Gear Tooth Chamferer, 10 Dia, Single Spindle REF#106
FELLOWS #100-180/60 CNC Max Dia 180, Single Spindle REF#106
CIMTEC #50 Finisher REF#106
CROSS #54 Gear Deburrer, 30 Dia, 18 Face REF#106
RED RING #24 Twin Spindle Dia 4 REF#106
GLEASON GTR-250 VG CNC 5-Axis REF#106
Gleason- Hurth Model ZEA 4, Max Dia 250mm, Max Module 5mm REF#106
Redin Model 36 universal Chamfering and Deburring Machine, Max OD 36, Twin spindle,
Tilt table REF#106
Cross 55 Gear Rounder, 18 Chuck, Hydraulic Unit REF#102
Cross 65, 10 Gear Pointer, Power Cylinder, Cutter, Change Gears REF#102
Cross 85 10 Chamfer, (2) Cutter Heads, Bevel, Spur, Helical REF#102
Samputensili SCT3 13.7, SM2TA 10, (5), 2003 REF#102
Samputensili SM2TA, 10, Max. Face Width 4, Hyd. Work Clamping, 1983-2003 REF#102
Mitsubishi MA30 CNC, 11PD, Fanuc Control, Powermate, 1999 (2) REF#102
GEAR HONERS
Kapp #CX120 Coroning 4.7 Dia REF#106
Red Ring GHD-12, 12 Dia, 5.5 Stroke REF#106
Red Ring GHG, 12 Dia, 5.5 Stroke REF#106
Kapp #VAC65 Coroning 10 Dia REF#106
National Broach GHG 18, Power Stock, Crowning, Variable Speed REF#102
Toyo T465 CNC, 160M Fanuc 5-Axis, Power Stock, Uses Fassler Tooling, REF#102
GEAR GENERATORS
GLEASON #37 Str. Bevel Planer, 6 Dia REF#106
GLEASON #496 Straight.& Spiral. 7.5 Dia REF#106
GLEASON 725-Revacycle, 6 Dia REF#106
GLEASON 726-Revacycle, 5 Dia REF#106
Farrel Sykes Model 12C herringbone max dia 264, max face width 60 REF#106
Farrel Model 5B herringbone gear generator. REF#106
Gleason 529 gear quench press, Auto cycle 16 Diam, New 1980 REF#106
Gleason 614 hypoid finishing machine, 10.5 pitch, dia 5.25 Max cone dist REF#106
Oerlikon/klingelnburg Model C28, Max dia 320 mm, Max Module 7.5 mm REF#106
Gleason Model 26 Quench press and Hypoid Generator Max OD 16, Max face Width Air
Cylinder REF#106
Gleason Model 36 Gear Quenching Press, Max Ring 28 OD, 8 Face, Universal REF#106
Gleason Model 450 HC CNC Hypoid Cutter, Face width 2.6, fanuc 150 Controls REF#106
Gleason 11 Spiral Bevel, 13, Stock Divider, Hyd. Chucking, Roughers & Finishers REF#102
Gleason 12, Gears, Gauges Tool Blocks REF#102
Gleason 16 Spiral Bevel, 18, 2-1/2 DP, Modified Roll, Chip Conveyor REF#102
Gleason 24 Rougher, Gears, Finishing Tool Holder REF#102
Gleason 116 Rougher & Finisher (6) REF#102
Gleason Phoenix 175HC CNC 1994 REF#102
Gleason 22 Rougher & Finisher (8) REF#102
Gleason 26 Spiral Bevel, 33-36, Mod. Roll, Stock Divider, Coolant, Change Gears REF#102
Gleason Phoenix 450HC, Spiral Bevel, 150MB Fanuc REF#102
Gleason 610 Combination Rougher & Finisher, 1988 REF#102
Gleason 608 & 609 Rougher & Finisher REF#102
Gleason 645 Spiral Bevel, Helical Motion, Chip Conveyor, Variable Rate of Roll REF#102
Gleason Cutters, 3 to 25 in stock, 1000 REF#102
GEAR GRINDERS
#27, #137, and #463 Gleason Hypoid Spiral Bevel gear grinder generating Cams
(2 full sets) REF#105
Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#105
REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#106
GLEASON #463, 15 Dia REF#106
Hofler model Rapid 2000L, CNC Grinder, Max OD 78, CNC Dressing REF#106
Matrix model 78, Reman CNC Thread grinder, 24 Dia, 86 grind Length, 106 between
centers REF#106
Mitsu Seiki Model GSW-1000 Gear Grinder REF#106
Reishauer RZ 362 AS, CNC Grinder, Max Dia 360mm REF#106
Sundstrand/Arter Model D12 Grinder REF#106
Teledyne-Landis Gear Roll Finishing Machine, 5 Diam, 42k lbs Rolling Force REF#106
Reishauer NZA, 12, Fassler Dresser, Many Extras, 1994 REF#102
Reishauer RZP, 4-8, Auto Loading, High Production, Use in Lab REF#102
Reishauer RZ301AS CNC, 13 Measuring System (3) REF#102
Reishauer ZB, 27.5 PD Gears, Coolant REF#102
Gleason 120 Curvic Coupling, 24 Max. Dia., Index Plates, Extras REF#102
Csepel FKP-326, Fassler Dresser, Like A Hogland NZA Reishauer, Super Cond. REF#102
National Broach SGK-24, Max. OD 31, ID 24, Spur & Helical, From Aircraft REF#102
Maag SH150, 60, Change Gears, 2-Pitch, Max. Face 23-1/2, Navy Surplus REF#102
GEAR RACK MILLERS/SHAPERS

MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#106
SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, 80 REF#106
GEAR SHAVERS
Red Ring #GCX-24" Shaver, 24 Dia, 33 Stroke REF#106
Red Ring #GCU-12, 12 Dia, 5 Stroke REF#106
Red Ring #GCY-12, 12 Dia, 5 Stroke REF#106
Red Ring GCI 24, 12.75 Dia, 5 Stroke REF#106
Kanzaki model GSP 320 Gear shaver REF#106
Red Ring GCU 12 Crowning, 1956 to 1988 (6) REF#102
Rex Ring GCX 24, Crowning, 12 Cutter Head, Taper Attachment, Long Table REF#102
Mitsubishi FB30, 12.2 CNC Fanuc, 1997 REF#102
Michigan 870, Crowning, Power Stocks, Very Light Use, Excellent REF#102
National Broach GCY 18, Crowning, Max. 19=1/2, Rebuilt or Under Power REF#102
National Broach GFF, Crowning, Heidenhein Scales, Servo Drives, 1993 REF#102
Raso Sicmat 400 CNC, Fanuc 16iM, Chip Separator, 2001 REF#102
GEAR TESTERS/CHECKERS (INCL CNC)

FELLOWS (1) RL-600 Roll Tester s/n 35814 REF#105
FELLOWS (1) 24H Lead Checker s/n 32289 REF#105
GLEASON (1) #14 Tester s/n 31907 REF#105
GLEASON (1) #6 Tester s/n 19316 REF#105
FELLOWS (1) 20 M Roller Checker REF#105
FELLOWS (1) 20 M w/ 30 Swing Roller Checker REF#105
FELLOWS (1) #8 Micaodex s/n 36279 REF#105
David Brown #24 Worm Tester REF#106
Gleason #4, #6, #13 and #17 Testers REF#106
Hofler EMZ-2602 Int/Ext Gear Tester 102 REF#106
Klingelnberg #PFSU-1600 Gear Tester-2001 REF#106
Kapp Hob Checker WM 410 REF#106
Maag #ES-430 Gear Tester REF#106
Maag #SP-130 Lead and Involute Tester REF#106
National Broach Gear Tester GSJ-12 REF#106
Oerlikon #ST2-004 Soft Tester REF#106
Maag #SP-60- Electronic Tester REF#106
Parkson #42N Worm Gear Tester REF#106
Vinco Dividing Head Optical Inspection REF#106
Gleason model 511 Hypoid tester Max Dia 20, max spindle centerline 3.5 REF#106
Klingelnberg Model PFSU-1600 63 Dia, 1.02 DP, Rebuilt REF#106
MAAG ES401 Pitch tester With Process Computer REF#106
Fellows 24M Involute, Response Electronic Recorder, Hot Pen REF#102
Fellows 36 Space Tester, Hot Pen Guaranteed REF#102
Fellows 8M Redliner, 13 5/8, Recorder (2) REF#102
Gleason 6, 7-1/2 Indicator Check, Pinion .00015, Gear .00001 REF#102
Gleason 17A Running or Rebuilt Guaranteed REF#102
Gleason 511, 20 Reconditioned in 2010 Guaranteed REF#102
Gleason 502, 10, Hydraulic Chucking, Automatic Backlash, Eliminator REF#102
Gleason 513 20 Gear, 10 Pinion Electronic Meter Reading of Sound (3) REF#102
Gleason 515, 24 REF#102
Gleason 520, 30, Hyd. Chucking, Auto Splash Doors/Backlash, Eliminator REF#102
Gleason 523, 20 Reconditioned, 2010 REF#102
Gleason 528 Cutter Inspection, Proximity Type Gage, 3.5-25, Conventional REF#102
Illinois 1731-3C, Hob & Worm Lead Tester, Electronic Recorder, Master Hob REF#102
Illinois 3412B-3C, 12 Involute with 1606 Electronic Recorder, Master Gauge REF#102
Illinois 3824-1-3B Spline & Spur Lead Tester, Max. Centers 52,
1606 Recorder REF#102
Illinois 3912-3C Lead Tester, 12, 1607 Electronic Recorder, 1980 REF#102
Klingelnberg PFS600 W/Masters, Recorder, Extras, 23.6, 0.59-23.6 REF#102
M&M 3015, 15 Gear Analyzer, P2 Computer Software, 12Mag. Chuck REF#102
GEAR THREAD & WORM, MILLERS/GRINDERS

BARBER-COLMAN #10-40, 10" Dia., 40" Length, 4 DP REF#106
EXCELLO #31L, External Thread Grinder, 5" OD, 20" Grind Length REF#106
EXCELLO #33 Thread Grinder 6 Dia 18 Length REF#106
HURTH #KF-33A Multi-Purpose Auto-Milling Machine 88 REF#106
LEES BRADNER #HT12x102, Extra Large Capacity REF#106
LEES BRADNER #HT 12"x 144" Thread Mill, 12" Dia, REF#106
LEES BRADNER # LT 8 x 24 8 Dia REF#106
HOLROYD 5A 24.8 Dia REF#106 LEES BRADBER WORM MILLER REF#106
MISCELLANEOUS
WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80 Centers,
12 Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965 REF#104
Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70"
Swing REF#105
GLEASON #529 Quench, 16" Diameter REF#106
Klingelnberg Model LRK-631 Gear Lapper REF#106
TOS SU & SUS Series Conv Lathes REF#103
TOS SUA Series CNC Flat-Bed Lathes REF#103
Gleason: Change Gears, Cutter Heads, Cams, Index Plates, Workholding REF#102
G & E: Change Gears, Arbors REF#102
Barber Colman: Change Gears, Arbors, Parts for All Models REF#102
Liebherr: Change Gears, Parts REF#102
Reishauer: Wheel Mounts REF#102
MARCH 2016
57
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SHAPER SERVICES, Inc.
98 Winery Road
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gearsolutions.com
Tel: 216-642-5900 Fax: 216-642-8837 5755 Canal Road Valley View, OH 44125
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ADVERTISER
INDEX
CONTENTS
PAGE NO.
Advent Tool & Manufacturing Inc.........................................................23

ALD Thermal Treatment Inc.................................................................45
Allen Adams Shaper Services Inc........................................................58
All Metals & Forge Group.....................................................................57
AWEA (Windpower '16)........................................................................55
Bourn & Koch Inc.................................................................................19
Broaching Machine Specialties............................................................30
Circle Gear & Machine Co Inc..............................................................23
Colonial Tool Group Inc........................................................................14
Engineered Tools Corporation............................................................IBC
Evonik Industries..................................................................................41
Federal Broach & Machine Company..................................................54
Gleason..................................................................................................2
GMTA (German Machine Tools of America).........................................49
Index Technologies..............................................................................58
Innovative Rack & Gear........................................................................58
Ipsen USA......................................................................................11, 58
KAPP Technologies...................................................................... IFC, 58
KISSsoft USA LLC.................................................................................9
Koro Sharpening Service.....................................................................58
Lawler Gear Corporation......................................................................58
McInnes Rolled Rings..........................................................................12
Mitsubishi Heavy Industries America Inc............................................BC
New England Gear.................................................................................7
Nordex Inc............................................................................................44
Pentagear Products.............................................................................27
P & G Machine & Supply Co Inc..........................................................59
Pinson Valley Heat Treating..................................................................21
Rave Gears & Machining......................................................................13
Raycar Gear & Machine Co.................................................................10
Russell Holbrook & Henderson Inc........................................................9
Schafer Industries................................................................................25
Seco/Warwick......................................................................................31
Solar Atmospheres...............................................................................58
STD Precision Gear & Instrument Inc..................................................21
The Broach Masters Inc.........................................................................4
Toolink Engineering Inc..........................................................................1
Ty Miles Inc...........................................................................................54
United Tool Supply...............................................................................59
MARCH 2016
59
Q& A
STEPHAN HECHT
EXECUTIVE VICE PRESIDENT
OELHELD GMBH
surface finish to Ra 0.6 . SintoGrind 353 is

a fully synthetic product that meets the chalI am from Germany, and Ive been living and lenge of the hardest Rockwell. And, DiaMill
working in the U.S. for about 30 years. I have 1100 HEF is a popular product when it comes
started and built-up two foreign-owned enti- to grinding alloys while keeping their shine.
ties. One company formulated and manufactured printing inks, while the other manufac- What are the biggest challenges you
tured automotive interior parts. I have been must address in the areas of lubrication?
with Oelheld for nearly four years, and my Formulating lubricants requires a lot of
responsibilities include general management, know-how. Oelhelds chemists understand
sales, and production.
the chemistry along with the tribology of
grinding very well and can, in turn, formulate
Please give us a brief history on Oelheld. excellent metal lubricants. The challenge is
It was 1887 when Carl Christian Held founded to strike a balance between performance and
Oelheld in Stuttgart, Germany. To put this in economics. There are excellent base oils and
perspective, Grover Cleveland was president, additives on the market, but their use might
the Star-Spangled Banner had 38 stars, and the be cost-prohibitive. The otherwise-perfect
Ford Model T was 21 years away from hitting product may not be affordable to the average
the road. In these 129 years, Oelheld became user and that is the challenge.
one of the most prolific specialists for coolants
and lubricants to the metal fabricating industry. What is it about Oelheld that sets it
Groundbreaking developments in the field of apart from others in the same industry?
EDM and grinding fluids, as well as forging A pioneering spirit is what sets Oelheld apart
lubricants, combined with consciousness efforts from its competitors. Oelheld has spearheaded
for the health of its users and the environment, the use of synthetics in metal lubrications and
have made Oelheld a worldwide success.
made headlines with its IonoPlus EDM fluid
In addition to its headquarters in Stuttgart, spiked with satellite electrodes. These are just
Oelheld has subsidiaries and manufacturing a couple examples of Oelhelds innovative
sites in France, the U.K., China, and the thinking on a product level.
U.S. Its products are sold in 34 countries.
Moreover, Oelheld adopted a program
Oelhelds clientele includes the tool grinding, called Human Technology, which means to
automotive, gear, aerospace, medical, stamp- care for man, environment, and machines. It
ing, mold-making, and forging industries.
is all geared toward a better future. Oelheld
products are all dermatology-tested and
Describe the products Oelheld offers
certified, are free from heavy metals, and
are low misting. Oelheld meets all requirethat are specific to the gear
ments according to the EUs chemicals policy
manufacturing industry.
Gear grinding was and still is an industry that (REACH), and Oelheld facilities are certified
is close to Oelhelds heart. Millions of cars to DIN EN ISO 14001.
in Europe and the U.S. cruise the highways
with gearboxes containing gears ground with Can you give us an example of how you
Oelheld products. Not only does the automo- solved a problem for a customer?
tive industry benefit from Oelhelds expertise, We are solving problems for customers almost
but also earthmoving, locomotives, mining, on a daily basis. Most are common problems,
and oil production equipment are dependent which are easily solved with the right fluid
on gears made with Oelhelds grinding oils. selection and recommendation or an adjustOelhelds most popular products that ment to the machine tool. Where it is gethave garnered accolades from our customers ting interesting and challenging at the same
include: DiaGrind 535-1, a universal gear time is when existing customers stretch the
grinding oil proven to speed up production by envelope beyond what their product can do.
up to 10 percent while achieving unparalleled We have an internationally operating gear
Will you tell us a little about yourself

and your role at Oelheld?
FOR MORE INFORMATION, go to www.oelheld.com
60
gearsolutions.com
manufacturer who is constantly pushing production output boundaries beyond what our
average clientele does. As a result, we have to
reformulate our product to avoid burns and
finishing flaws. This requires some serious
efforts in terms of time and manpower. The
end result, however, is rewarding for both
parties. The customer is happy that they can
produce faster, and Oelheld ends up with
another performance offering that was not
necessarily on our development schedule.
What is in the future for Oelheld?

Oelheld will continue to do research that
is cutting-edge. Currently, we are testing a
new family of base fluids that holds a lot of
promise for further enhancing production
speed. Oelheld will continue to crusade new
ideas, even if it is not the easiest way to get
new business fast. Also, we are busy putting
up a new lab and technology center at our
headquarters in Stuttgart, while here in the
U.S., we are building a brand-new manufacturing facility.
Whats your opinion on the health

of the lubrication industry related to
gear manufacturing?
There is a lot of talk about dry hobbing and
grinding, and there is no doubt in our minds
that these technologies will gain traction for a
number of reasons. Cost, space, and environment are some of the drivers. However, the
latest major expansions some of the big players in the gear industry completed in recent
years and months all involved the installation
of wet machines. Given the amount of money
invested, we believe that the gear industry will
not turn on a dime and go all dry.
For Oelheld, we will continue our quest for
developing performance products to further
enhance production speed and output. And
our advice to readers is: Dont bury your
head in the sand. Go out and evaluate new
products. Increased output may save you
thousands if not millions a year.
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Investigations On The Efficiency of Worm Gear Drives: Company Profile

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GEAR SOLUTIONS MAGAZINE

INVESTIGATIONS ON THE EFFICIENCY OF WORM GEAR DRIVES

from small to large

Generating Grinding 8mm- 1,250mm Profile Grinding 8mm- 8,000mm

2870 Wilderness Place Boulder, CO 80301

As a highly technical specialty lubricants formulator and manufacturer, Syn-Tech Ltd.

Investigations on the Efficiency

By Eva-Maria Mautner, Werner Sigmund, Johann-Paul Stemplinger, and Karsten Stahl

Shear Stability Is Key to Proper EAL Gear Oil Selection

An Update on Broaching Technology

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and Universal Gear Company

Call 530-885-1939 or visit

Reports, data, and developments to keep

Gleason Announces Availability of

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Welcome to this issue

Anna Claire Howard

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