Gear Process Engineering

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1 A Jump Start on Gear Process Engineering The intensive 3-day course is designed to provide attendees with a comprehensive overview of the fundamentals involved in 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 manual for 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 Benefits Finding qualified gear process engineers is a common challenge in the gear manufacturing industry and companies are often faced with the need to train internal resources on their own. However, this can be a very long process and can put a strain on existing engineering staff. By utilizing the AGS training experience, trainees can acquire a comprehensive overview of gear processing from leading industry experts; resulting in a skilled process engineer much faster and for far less cost. Dates and Times: March 7, 8, 9, :30 AM to 5:00 PM (Daily) Registration Deadline: February 15, 2017 Course: An Introduction to Gear Process Engineering Register Now for the Upcoming Session Call or register online at Location: Northern Illinois University Naperville Conference Center 1120 E Diehl Rd #150 Naperville, IL Cost: 3-Day Seminar (including breakfast and lunch) $1,925 Hotel Accommodations: Hampton Inn Chicago/Naperville Across the street from the Conference Center 1087 East Diehl Rd., Naperville Mention the AGS Gear Process Training Seminar for Reduced Rates, LLC 1808 Ogden Ave, Lisle, IL (800)

2 About the Instructors The seminar features industry experts for providing valuable insights into a full range of operations critical to the gear process engineer. One of the most pressing challenges facing American manufacturing today is the shortage of skilled people for any number of critical roles. This is certainly the case with the gear industry. While strides are being made to prepare young people for vocations in manufacturing, the fact that a significant amount of expertise will be leaving the workforce as Baby Boomers retire, threatens the collective expertise of this critical industrial sector. For this reason, Arvin Global Solutions (AGS) is dedicating our efforts to develop and facilitate training opportunities with the primary goal of transferring the knowledge of today's gear industry experts to the next generation. Joseph L. Arvin President and CEO Bruce Roberge Facilitator, Gear Processing Specialist The Quote Machine LLC - President Previously: Rave Gears - President Northstar Aerospace - Business Development Manager and Forward Planner Arrow Gear Company - Manufacturing Engineering Manager, European Project Manager, Process Engineer Ron Green Gear Cutting Eaton Corporation - Chief Engineer (ret.) Involving design, quality, and manufacturing for automotive and truck axles and transmissions, also involved in developing AGMA, SAE, and ISO standards for gearing and splines Kevin Walsh Cylindrical Grinding Overton Chicago Gear - VP Operations (ret.) Previously: General Manager, Engineering Manager, Quality Manager, Plant Manager, Department Manager About the AGS Gear Industry Training Series Ongoing Extra-Academic training will continue to be a critical need of the gear industry, and meeting this need is the overall objective of the AGS Gear Industry Training Series. Matt Mondek Turn, Mill, and Drill Mondek Solutions - President Previously: Reliance Gear Corporation - President/CEO American Gear Manufacturers Association (AGMA) - Chairman of the Board Cotta Transmission, LLC - President Outboard Marine Corporation - Director, Management and Engineering Positions Al Swiglo Heat Treatment NIU College of Engineering & Engineering Technology and IIT Alion Science and Technology - Associate Director of Manufacturing Processes Research (ret.) ASM International Fellow Award AGMA - Metallurgy Committee Member Brad Foote Gear Works - Director of Metallurgy Chuck Shultz Gear Finishing - Lap, Hone, Grind Beyta Gear Service - Principal, Gear Consultant Previously: Senior Executive and Engineering positions at: Brad Foote Gear Works Milwaukee Gear Company Quaker City Gear Works Ex-Cell-O Corporation Chicago Gear/D.O. James Mike Steele Quality NorthStar Aerospace - Responsible Level 3 (instructor) Moraine Valley Community College - Instructor Consultant - NDT and Nadcap Certification Previously: Arrow Gear - Level 3 NDT Inspector Ogden Ave, Lisle, IL (800)

3 About the Seminar The upcoming seminar, taking place on March 7, 8, and 9, 2017, will be held at the Northern Illinois University - Naperville Conference 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 experience is required to successfully perform this function. However, formal training for this skill set is not available through traditional academic offerings. The result is a shortage of engineers for this role in gear manufacturing. Left with limited options for recruiting skilled, experienced process engineers, gear companies are often faced with the necessity of internally training employees from their organizations. By taking this route, companies must encroach on the valuable time 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 principles involved in processing a gear for the manufacturing process. This will involve lectures as well as hands on experience through exercises. The trainee will also receive a training manual that documents all of the material presented during the seminar. Upon completing the training the trainee will be able to perform simple processes, while having an awareness of issues of concern, such as operational sequences, proper manufacturing tolerances, heat treat distortion, locating surfaces, and quality. When the trainee returns to their company, they will require less direct training from engineering staff resources. In addition, in the event that internal resources are unable to spend adequate time with the trainee, AGS offers a follow up mentorship program. A specifically assigned mentor will be available at an hourly rate to answer questions, review processes, provide cost reductions suggestions, and make recommendations on any additional training required by the trainee Ogden Ave, Lisle, IL (800)

4 Course Topics The following is an outline of key topics that will be presented during the Gear Process Engineering Training Seminar. Session 1 Introduction (4 hours) Presenter: Bruce Roberge DAY 1 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 Gear Process Engineering Training Course Outline Course Topics Page 1

5 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 /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 Gear Process Engineering Training Course Outline Course Topics Page 2

6 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. : 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 to (0.127 to 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? Gear Process Engineering Training Course Outline Course Topics Page 3

7 Session 4 Heat Treatment (4 hours) Presenter: Al Swiglo 1. If the carburizing and hardening process is required, are there areas to be nonhardened. 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, 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. 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 Gear Process Engineering Training Course Outline Course Topics Page 4

8 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 Gear Process Engineering Training Course Outline Course Topics Page 5

9 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. Gear Process Engineering Training Course Outline Course Topics Page 6

10 Processing Capabilities Worksheet Page 1 Turning Finish Turning Length Tolerance (+/ ) # of Axes Mill, Drill, Broach Milling Drilling Broaching Length of Cut Tolerance (+/ ) Location Accuracy Length of Spline Major Dia. of Spline # of Axes Gear Cutting (Parallel Axis) Hobbing Helical/Herringbone Shaping Worm Gear Tooth Cut Diam. Pitch & Tolerance (+/ ) Width # of Axes Length of Spline Helix Angle Gear Cutting (Bevel) Spiral Bevel Tooth Cut Coniflex Tooth Cut Hypoid Bevel Tooth Cut Diam. Pitch & Shaft Angle Face Width # of Axes

11 Processing Capabilities Worksheet Page 2 Heat Treatment Carburize and Harden Through Harden Induction Harden Vacuum Harden Nitriding Die Quenching Straightening Deep Freeze Draw Furnace Free Quench Length Cylindrical Grinding Grind ID Grind Center Grind Thread Grind Surface Grind Honing Length Tolerance (+/ ) # of Axes Surface Finish Finishing (Parallel Axis) Spur Tooth Grind Helical Tooth Grind Internal Spur Grind Gear Lapping Gear Honing Shaving Diam. Pitch & Surface Finish Width # of Axes Length of Spline Helix Angle

12 Processing Capabilities Worksheet Page 3 Finishing (Bevel) Spiral Bevel Tooth Grind Hypoid Tooth Grind Lapping Diam. Pitch & Shaft Angle Face Width # of Axes Surface Finish Other Operations Deburring Plating Blasting Nital Etch Stress Relief ISF Magnaflux Shot Peening OTHER OTHER OTHER Max Length

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