course: an introduction to gear process engineering - gear process engineering info... · a jump...

Arvin Global Solutions, LLC • 1808 Ogden Ave, Lisle, IL 60532 • (800) 815-2303 • [email protected]

A Jump Start on Gear Process Engineering

The intensive 3-day course is designed to provide attendees with a comprehensive overview of the fundamentals involvedin successful processing of gears for manufacturing.

In this course, the attendees will learn,• Evaluating the blueprint for processing• Determining equipment and sequences required for

producing the part • Strategies for efficient, cost saving processing• Review of major production operations for

processing insights• Principles of locating surfaces and stock allowance• The impact of heat treatment• Quality - Surface Temper Etch and Magnaflux• And much more!

Upon completing the course, attendees will have processed sample gears, and will fully understand the core principles -preparing them for further on-the-job refinement of their skills. Attendees will also receive an indepth training manualfor future reference on key topics.

Who Should Attend• Newly degreed manufacturing engineers• New hires with little process engineering experience• Experienced shop personnel transferring into Engineering• Prerequisites include blueprint reading, shop math, a good knowledge of gear manufacturing

and/or general metal working experience

Training BenefitsFinding qualified gear process engineers is a common challenge in the gear manufacturing industry and companies areoften faced with the need to train internal resources on their own. However, this can be a very long process and can puta strain on existing engineering staff. By utilizing the AGS training experience, trainees can acquire a comprehensiveoverview of gear processing from leading industry experts; resulting in a skilled process engineer much faster and for farless cost.

Course:An Introduction to

Gear Process Engineering

Register Now for the Upcoming SessionCall 800-815-2303 or register online at www.ArvinGlobalSolutions.com

Dates and Times:March 7, 8, 9, 2017

7:30 AM to 5:00 PM (Daily)

Registration Deadline:February 15, 2017

Location:Northern Illinois University

Naperville Conference Center1120 E Diehl Rd #150Naperville, IL 60563

www.niunaperville.niu.edu630-577-9101

Cost:3-Day Seminar

(including breakfast and lunch)$1,925

Hotel Accommodations:Hampton Inn Chicago/Naperville

Across the street from the Conference Center1087 East Diehl Rd., Naperville

630-505-1400Mention the AGS Gear Process Training Seminar

for Reduced Rates

www.ArvinGlobalSolutions.com1808 Ogden Ave, Lisle, IL 60532

(800) [email protected]

One of the most pressing challenges facing Americanmanufacturing today is the shortage of skilled people forany number of critical roles. This is certainly the case withthe gear industry. While strides are being made to prepareyoung people for vocations in manufacturing, the fact that asignificant amount of expertise will be leaving the workforceas Baby Boomers retire, threatens the collective expertise ofthis critical industrial sector.

For this reason, Arvin GlobalSolutions (AGS) is dedicating ourefforts to develop and facilitatetraining opportunities with theprimary goal of transferring theknowledge of today's gear industryexperts to the next generation.

Ongoing Extra-Academic trainingwill continue to be a critical need ofthe gear industry, and meeting thisneed is the overall objective of theAGS Gear Industry Training Series.

Joseph L. ArvinPresident and CEO

Arvin Global Solutions

About the AGS Gear IndustryTraining Series

About the InstructorsThe seminar features industry experts for providing valuable insights into a full range of operations critical to the gearprocess engineer.

Bruce RobergeFacilitator, Gear Processing SpecialistThe Quote Machine LLC - PresidentPreviously:Rave Gears - PresidentNorthstar Aerospace - Business DevelopmentManager and Forward PlannerArrow Gear Company - ManufacturingEngineering Manager, European ProjectManager, Process Engineer

Matt MondekTurn, Mill, and DrillMondek Solutions - PresidentPreviously:Reliance Gear Corporation - President/CEOAmerican Gear Manufacturers Association(AGMA) - Chairman of the BoardCotta Transmission, LLC - PresidentOutboard Marine Corporation - Director,Management and Engineering Positions

Ron GreenGear CuttingEaton Corporation - Chief Engineer (ret.)Involving design, quality, and manufacturingfor automotive and truck axles andtransmissions, also involved in developingAGMA, SAE, and ISO standards for gearingand splines

Al SwigloHeat TreatmentNIU College of Engineering & EngineeringTechnology and IIT Alion Science andTechnology - Associate Director ofManufacturing Processes Research (ret.)ASM International - 2011 Fellow AwardAGMA - Metallurgy Committee MemberBrad Foote Gear Works - Director ofMetallurgy

Kevin WalshCylindrical GrindingOverton Chicago Gear - VP Operations (ret.)Previously:General Manager, Engineering Manager,Quality Manager, Plant Manager, DepartmentManager

Chuck ShultzGear Finishing - Lap, Hone, GrindBeyta Gear Service - Principal, Gear ConsultantPreviously:Senior Executive and Engineering positions at:Brad Foote Gear WorksMilwaukee Gear CompanyQuaker City Gear WorksEx-Cell-O CorporationChicago Gear/D.O. James

Mike SteeleQualityNorthStar Aerospace - Responsible Level 3(instructor)Moraine Valley Community College - InstructorConsultant - NDT and Nadcap CertificationPreviously:Arrow Gear - Level 3 NDT Inspector

About the SeminarThe upcoming seminar, taking place on March 7, 8, and 9, 2017, will be held at the Northern Illinois University - NapervilleConference Center at 1120 E Diehl Rd #150 Naperville, Illinois.

Gear Process Engineering is a critical role in the gear manufacturing process. A great deal of knowledge and experienceis required to successfully perform this function. However, formal training for this skill set is not available throughtraditional academic offerings. The result is a shortage of engineers for this role in gear manufacturing. Left with limitedoptions for recruiting skilled, experienced process engineers, gear companies are often faced with the necessity ofinternally training employees from their organizations. By taking this route, companies must encroach on the valuabletime of existing staff to bring these trainees up to speed, and this learning curve can take many months, if not years,before the trainee is able to work efficiently on their own.

For this reason, AGS is offering the three day seminar to provide engineer trainees with a solid overview of the principlesinvolved in processing a gear for the manufacturing process. This will involve lectures as well as hands on experiencethrough exercises. The trainee will also receive a training manual that documents all of the material presented during theseminar. Upon completing the training the trainee will be able to perform simple processes, while having an awarenessof issues of concern, such as operational sequences, proper manufacturing tolerances, heat treat distortion, locatingsurfaces, and quality.

When the trainee returns to their company, they will require less direct training from engineering staff resources. Inaddition, in the event that internal resources are unable to spend adequate time with the trainee, AGS offers a follow upmentorship program. A specifically assigned mentor will be available at an hourly rate to answer questions, reviewprocesses, provide cost reductions suggestions, and make recommendations on any additional training required by thetrainee.

www.ArvinGlobalSolutions.com1808 Ogden Ave, Lisle, IL 60532

(800) [email protected]

Gear Process Engineering Training – Course Outline Arvin Global Solutions Course Topics – Page 1

Course Topics The following is an outline of key topics that will be presented during the Gear Process Engineering Training Seminar.

DAY 1 Session 1 – Introduction (4 hours) Presenter: Bruce Roberge

1. The role of the Process Engineer Creating an efficient path from blueprint to finished part The Process Engineer must know the type and capability of the plant’s

equipment. COMMENT: To assist the trainee in understanding this concept,

they will be presented with a sample copy of a Processing Capabilities Worksheet. This will contain a list of the general types of machines used in gear manufacturing with the general capabilities for size and tolerances which can be maintained, to be used when they work through a sample process exercise during Day 3 of the training. Equally valuable, each will be given a digital copy of an Excel spreadsheet that they can use later for work at their company to document their available machines and capabilities.

The first question to ask: “Have we manufactured a similar part before? Processing to make a profit (less cost with good quality) Don't over look vital info on the PO or specs on the print What does the Process Engineer need to look for before starting the

processing? (Note: the trainee doesn’t have to understand all technical aspects.)

Evaluating the blueprint – Types of gear – spur, spline, helical, bevel, worm, etc – Geometry configurations which generally cause machining problems

– (highlights only) – Configuration and potential heat treat distortion concerns –

(highlights only) – Type of Material – Bar Stock or Forging – Heat Treatment required

o Through hardening o Induction hardening o Carburization & hardening o Vacuum o Nitriding o Hardened areas vs. non‐hardened areas


– Tolerances – Surface Finishing & Platings – Dynamic Balancing

2. Looking at the blueprint to determine the type of equipment required to manufacturer a specific part – either in‐house or out sourced. Looking at a typical gear, is the following equipment required? Turing ‐ Milling ‐ Drilling ‐ Broaching OD/ID, surface, & thread grinding Gear cutting Heat Treating Gear Lapping Honing Gear Grinding Gear Shaving Gear Shaping

3. Operational Sketches ‐ Typically operational sketches are provided for critical operations.

Session 2 – Turning, Milling, and Drilling (3 hours) Presenter: Matt Mondek

1. Turning

Turning is the first step in the process where the part begins to take shape. Turning should be thought of as the foundation of the part as it impacts many subsequent operations. Discussion topics should include: Considerations for machining from Bar or Forging (chucking diameter needed) Designate chucking (locating) surfaces for turning both sides Typical dimensions and tolerances for turning both sides such as:

o When to leave stock for grinding and heat treat distortion – and why o Where to have close tolerances when open tolerances are permitted

on the blueprint and why o Required locating surfaces for post turning operations o Dimensions to be held for compensation of heat treat distortion o Will further machining be necessary after heat treat due to distortion?

2. Milling Locating (chucking) surfaces Basic dimensions and tolerances Special tooling required Surface finishes requirements or extreme tolerance Any timing required Will further machining be necessary after heat treat due to distortion?

3. Drilling Locating (chucking) surfaces


Basic dimensions and tolerances Special tooling required Surface finishes requirements or extreme tolerance

DAY 2 Session 3 – Gear Cutting (2 hours) Presenter: Ron Green

1. Types of gear cutting, and what the process engineer needs to know. Comment: This content will be limited to basic geometric differences between gearing types. Photos of each type of gear will be provided as orientation. The trainee will be told to refer to the gear data on the blueprint for specifics.

2. Gearing Types Spur Spline (external and/or internal) Helical Herringbone Straight bevel Coniflex Spiral bevel Hypoid bevels Worm

3. Insuring that there is proper cutter clearance. 4. Based on the blueprint gear data or tooth surface finish, determine if the gear

teeth require lapping, honing, or grinding. 5. If the gear teeth require grinding, considering the geometric configuration and

part size, and determining the amount of stock to be left on the gear teeth. For grinding, typically 0.005 to 0.007 (0.127 to 0.178 mm) stock per flank

6. Determine if work holding tooling is available ‐ is this is the responsibility of the process engineer?

7. Determine if cutting tools are available or must be ordered – is this the responsibility of the process engineer?

8. From the gear data on the blueprint, determine the type of machine required ‐ is there cutter clearance requiring shaping or smaller diameter cutter

9. Deburring gear teeth before heat treating 10. Broaching

Basic tooling required and locating surfaces Surface Finish requirements or extreme tolerancing. Timing Requirements Will further machining be necessary after heat treat due to distortion?


Session 4 – Heat Treatment (4 hours) Presenter: Al Swiglo

1. If the carburizing and hardening process is required, are there areas to be non‐hardened. Using copper plating or other stop‐off materials to be applied to various areas as indicated on the blueprint.

2. Basic overview of various types of heat treating equipment Through hardening Induction hardening Carburizing and Hardening Die quenching Vacuum

Nitriding General guidelines as to expected size changes and distortion due to heat

treatments and ways to minimize or predict them 3. Basic discussion on determining if die quenching is required – is tooling required

or quench plug 4. Are Temper, draw, and deep freeze required in a spec? Is this decision left up to

the heat treat department? 5. Is straightening required and if so is this the responsibility of the heat treat

department? 6. Is surface hardness and core hardness on the blueprint or spec, the responsibility

of the heat treat department or specified by the Process Engineer? 7. Heat treat inspection – General guidelines as to specifying pin size diameters,

run out, and lengths to be held after heat treating? 8. A brief discussion as to when to consider turning thin webs after Carburization

and before hardening or after hardening ‐ or not. 9. General discussion regarding best racking or hanging to minimize distortion.

Session 5 – OD, ID, Surface and Thread Grinding (2 hours) Presenter: Kevin Walsh

1. The following operations may be required before gear cutting and heat treating, and a discussion on important considerations will be covered. OD Grinding ID Grinding Thread Grinding

2. A general discussion relevant to dimensions, length and radius to be held and why

3. Typical manufacturing locating surfaces, concentric diameters, faces, and radius is to be held, if different than the blueprint and why

4. A discussion regarding the need for Surface Temper Etch or Magnaflux after grinding and prior to heat treating


DAY 3

Session 6 – Gear Finishing: Lapping, Honing, and Grinding (2 hours) Presenter: Chuck Shultz

1. If the gear teeth or splines are to be lapped, honed, shaved or ground, this can typically be determined by the blueprint.

2. If the blueprint does not specify, general guidelines will be given as to when to lap, hone, shave, or grind.

3. The gear finishing will determine the type of machine tools required. 4. Indicate locating surfaces and tooling required to maintain gear tooth tolerances. 5. Tolerances to be maintained are typically listed on the blueprint. 6. Cautions regarding surface tempering, re‐hardening, and cracks. 7. Can cracks be present without the presence of surface tempering? 8. The blueprint should specify the gear tolerances, and if not, there should be a

quality level such as an AGMA number. 9. In some instances operational sketches are provided specifying the tooth

tolerances. 10. The importance close tolerance locating (chucking) surfaces and work holding

tooling to control runout and accumulated spacing error. 11. The effect of excessive runout and/or accumulated runout when the gear is in

the gearbox. 12. How runout can cause excessive stock removal in areas of the gear causing the

depth of case hardness to go under minimal tolerances 13. Run out can cause surface tempering and cracks 14. The increasing demand for shot peening and its advantage for life cycle increase. 15. Time Permitting: A brief explanation of the following:

Pin size or backlash Involute profile or V&H (EPG) Parallel axis gearing ‐ lead error and/or crowning Surface finish Tooth Spacing Hole depth Radius

(A handout will be provided in the training manual showing examples of the above.)

16. Time Permitting: A brief explanation as to why all of the tolerances are important to be held for the performance of the gear in the final assembly.

Session 7 – Quality (2 hours) Presenter: Mike Steele

1. Surface Temper Etch After Grinding ‐ Chemical Method


The purpose of Surface Temper Etch Grinding burns, re‐hardening and their impact on gear performance The process of Surface Temper Etch When is it performed in the manufacturing process? The importance of Hydrogen embrittlement relief – what it is and how is it

performed 2. Magnaflux

The reasons for performing Magnaflux When is Magnaflux performed?

Session 8– Final Operations in the Manufacturing Process (1 hour) Presenter: Bruce Roberge

1. Final operations include: Surface Finishing – plating Shot peening Balancing – per blueprint Final Inspection Final packaging for shipment or storage – the importance of oiling parts

Session 9 – Preparing a Basic Process (3 hours) Presenter: Bruce Roberge

1. Now that the trainees have received the scope of the information required for processing a job, they will first see how a basic process is performed, and then they will have the opportunity to perform a basic process on their own.

2. Demonstration on how to process a job – by the instructor 3. The role of operation drawings – (Note: It will be explained to the trainees that

the process of preparing operation drawings is beyond the scope of this training, and will require CAD skills)

4. EXERCISE: Trainees break into 3‐4 person teams and will work from a blueprint to prepare their own process

5. The group will then discuss the results of the sample process.

END

Note: See following pages for the Processing Capabilities Worksheet that will be used during the training sessions.

Processing Capabilities Worksheet Page 1

TurningOD

Max.Length Max.

Tolerance (+/‐)

Runout Min.

# of Axes Comment

Finish Turning

Mill, Drill, BroachOD

Max.

Length of Cut Max.

Tolerance (+/‐)

Runout Min.

Location Accuracy

Min.

Length of

Spline Max.

Major Dia. of Spline

Max.

# of Axes

Comment

Milling DrillingBroaching

Gear Cutting (Parallel Axis)

OD Max.

Diam. Pitch

Max. &

Min.

Tolerance (+/‐)

Width Max.

Runout Min.

# of Axes

Length of Spline Max.

Helix Angle Max.

Comment

HobbingHelical/HerringboneShapingWorm Gear Tooth Cut

Gear Cutting (Bevel)

OD Max.

Diam. Pitch

Max. &

Min.

Shaft Angle Max.

Face Width Max.

Runout Min.

# of Axes

Comment

Spiral Bevel Tooth CutConiflex Tooth CutHypoid Bevel Tooth Cut


Heat TreatmentOD

Max.Length Max.

Comment

Carburize and HardenThrough HardenInduction HardenVacuum HardenNitridingDie QuenchingStraighteningDeep FreezeDraw FurnaceFree Quench

Cylindrical GrindingOD

Max.Length Max.

Tolerance (+/‐)

# of Axes

Runout Min.

Surface Finish

Comment

OD GrindID GrindCenter GrindThread GrindSurface GrindHoning

Finishing (Parallel Axis)

OD Max.

Diam. Pitch

Max. &

Min.

Surface Finish

Width Max.

Runout Min.

# of Axes

Length of Spline Max.

Helix Angle Max.

Comment

Spur Tooth GrindHelical Tooth GrindInternal Spur GrindGear LappingGear HoningShaving


Finishing (Bevel)

OD Max.

Diam. Pitch

Max. &

Min.

Shaft Angle Max.

Face Width Max.

Runout Min.

# of Axes

Surface Finish

Comment

Spiral Bevel Tooth GrindHypoid Tooth GrindLapping

Other OperationsMax OD

Length Max.

Comment

DeburringPlatingBlastingNital EtchStress ReliefISFMagnafluxShot PeeningOTHEROTHEROTHER

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