MAAG - Gear Solutions Magazine

Reishauer’s Next-GenerationGEAR GRINDERLEISTRITZ ImprovesWORM GEARS with WHIRLINGWeissQ&A with Norbertof FrencoA MEDIA SOLUTIONS PUBLICATIONUpgrading MAAG TechnologyIntegrated Software from UTSCompany Profile: NEW ENGLAND GEAROCTOBER 2003

ENHANCED PERFORMANCE,POWER, AND PRECISIONPRECISION KLINGELNBERG & GLEASON-CUTSPIRAL BEVEL GEAR SETS FROMwith German engineeredWELTERrebuilt and cnc-retrofittedgear manufacturingSpecializing in HPGS-Hard Cutting,C N C - g r i n d i n g , Te s t i n g , a n d L a p p i n g o fequipment fromSpiral Bevel Gears and Pinions, includingWELTERin-house heat treating with completestate-of-the-art process.USA Sales Office(For Machine Tools Only)Laurens Trading Corp.“Gear Machinery Specialists”10601 Glendale Road Cincinnati, OH 45215phone (Mohawk office) 513 771-1952fax 513 771-5120 cell 513 646-2987email n.laurens@worldnet.att.netRICHARD WELTER Maschinen& Zahnradfabrik GmbHKarl-Kammer-Str. 7 77933 Lahr, Germanyphone 49 7821 923-0 fax 49 7821 923129email zahnrad@welter-lahr.devisit our website @ www.welter-lahr.dePlease visit us at Booth #634at Gear Expo 2003 in October!!!

For Your Gear SolutionsGEAR HOBBERSIntroducing theNew 100H Series IIincorporates many of the standardfeatures and performance of the200/400H at a very economical price.Standard Features Include: NUM 6-axis digital system Full machine enclosure withstainless steel covers for dry cutting Increased hob capacity 2000 rpm hob spindle No Hydraulics!GEAR SHAPERSIntroducing theNew MS300 Gear Shaping MachineStandard Features Include: GE Fanuc 16i 7-axis system 300mm of upright adjustment 150mm of stroke length Spindle speeds up to 2000 SPM Other sizes availableGEAR INSPECTIONSYSTEMSIntroducing theNew Roto-Check RC400-12Standard Features Include: Delta Tau control system True Windows based graphicalsoftware with real time feedback Various models available Retrofit packages available for yourexisting gear inspection systems2500 Kishwaukee St. Rockford, IL 61104 815/965-4013 fax tt.netINCBOURN&KOCHVisit us atGEAR EXPOBooth #1134

Visit us at GEAR EXPO 2003 — Booth #500

departmentsOCTOBER 2003A MEDIA SOLUTIONS PUBLICATION6 industryNEWSNew products, trends and developments in the gear industry17 terryMcDONALD — Safety MattersIn these litigious times—and with the rising cost of workman’s comp and medicalinsurance—it’s more important than ever to foster safe workplace practices.features18 CompanyProfile – New England GearBy Russ WillcuttJeff Barnes knows Fellows gear machines, and those “in the know” considerhim the primary source for rebuilt equipment, parts, and service.pg. 2822 High-PerformanceGrinding Solutions for Small or Large LotsBy Dennis RichmondReishauer’s RZ 400 is like no other generating grinder on the market today,and it can efficiently grind batches of five—or 5,000.28 More MAAG for your MoneyBy Norman C. LaurensSince MAAG machines are known for their precision and durability,savvy owners are upgrading their existing equipment.pg. 4040 TransformingDesign with Integrated Gear SoftwareBy Russ WillcuttAfter years of research and real-world experience, Universal TechnicalSystems introduces the IGS package for comprehensive gear design.48 TheWhirling Process for Improved Worm GearsBy Ralph WehmannModern design, machining, and heat treating amount to huge savingsfor worm-gearing manufacturers.pg. 48Special thanks to Nachi Machiningfor contributions to our cover artwork.Layout design by Andy Spain forGear Solutions magazine.64 Q&A — Norbert WeissWe talk with a Frenco authority.special advertising sections57 MACHINES60 MARKETPLACEgearsolutionsonline.com63 INDEX OF ADVERTISERS OCTOBER 2003 GEAR SOLUTIONS3

From the PublisherDDeadlines, commitments, obligations, promises all familiar words togear manufacturers and magazine publishers alike. But you’ve got to getout of the office and mingle with your colleagues every once in awhile,else you’ll lose sight of the big picture. And that’s just the opportunitythat Gear Expo provides: the chance to see old friends, make new ones,and check out all the exciting advancements being made in this endlesslyfascinating industry.In the same way, we’ve worked to gather news of cutting-edge equipment,software, concepts, and processes in the October issue of Gear Solutions thatshould help you in your never-ending quest to excel. In this issue of the magazine you’ll find articles on Reishauer’s RZ 400 grinding machine, which takes amajor step forward in producing excellent gears of any lot size, and on thesense behind considering whirling and heat induction into your worm-gearmanufacturing process. You will also read about the years of hard work andresearch that Universal Technical Systems has put into developing the mostcomprehensive gear-design software available on the market today. And forthose of you who are true MAAG believers, you’ll especially enjoy the articleon the many benefits of upgrading your workhorse equipment with new tooling and electrical packages. Again, we present this material in the hopes that itwill help you be more productive and efficient in your work—and to save acouple of dollars along the way.In line with this philosophy is our company profile of New EnglandGear-the premier source for rebuilt and reoutfitted Fellows machines andparts in the United States. Jeff Barnes, the company’s president andfounder, has a world of experience to offer, and his knowledge can beaccessed at the touch of a couple of numbers on your telephone keypad.We’re also pleased to share our conversation with Norbert Weiss, ofFrenco, who discusses the company’s history, strengths, and future plans.As always, Terry McDonald has found a way to get right to the heartof why safety really does matter in the workplace-especially in light of therising cost of workman’s compensation and medical insurance. Beyondthat, personal-injury lawsuits have almost become commonplace, so thejobs of safety professionals have become that much more important totheir employer’s bottom line. Read Terry’s words and remember that,quite often, it really is the little things that matter the most.So we hope that you’ll enjoy reading this issue of Gear Solutionsmagazine, and also that you’ll visit our companion Web site at[www.gearsolutionsonline.com], where you will find machine listings andarchives of all the articles and profiles we’ve published in our first year ofproduction. We also hope you’ll consider joining our “storefront community,” which will get your name into the hands of the very people whoneed to see it.Also, please stop by our Gear Expo booth #833—we look forward toseeing you!David C. CooperPublisherGear Solutions magazinedcooper@gearsolutionsonline.com(800) 366-21854GEAR SOLUTIONS OCTOBER 2003 gearsolutionsonline.comPublished byMedia Solutions, Inc.P.O. Box 383185Birmingham, AL 352381-800-366-2185David C. CooperPUBLISHERChad MorrisonVICE PRESIDENTTeresa HallOPERATIONS/CIRCULATIONMichele HallADMINISTRATIVEASSISTANTPRODUCTIONAndy SpainART DIRECTOREDITORIALRuss WillcuttMANAGING EDITORCONTRIBUTINGWRITERS:Norman C. LaurensTerry McDonaldDennis RichmondRalph WehmannThe views expressed by those noton the staff of Gear Solutionsmagazine, or who are not specificallyemployed by Media Solutions, Inc.,are purely their own. All “industrynews” material has either beensubmitted by the subject companyor pulled directly from their corporateWeb site, which is assumed to becleared for release. Commentsand submissions are welcome,and can be submitted toeditor@gearsolutionsonline.com.

industryNEWSNew Products, Trends and Developments in the Gear IndustryBourn & KochIntroduces 100H Series IIHobbing MachineThe 100H Series II Hobbing Machineincorporates the design and featuresof the Bourn & Koch 200H/400HSeries II Hobbing Machines. Standardfeatures include six CNC controlledaxis; radial in-feed, axial feed, hobshift, hob spindle, work spindle, andhob swivel. New features include 6”of hob shift, standard Num 1050CNC controller with Num digital driveswith absolute encoders, conversational software, 2000 rpm hob spindlewith five continuous Hp & 10 maximum peak Hp, full machine enclosure with stainless steel slopedguarding for wet or dry cutting capabilities, no hydraulics and easy placement tail center assembly withadjustable clamping force up to 500lbs 3” stroke live center.100H Series II Hobbing Machinefrom Bourn & KochThe 100H accommodates parts witha maximum swing diameter of 10” anda cutting diameter of 4.5”. Typicalquality results of AGMA Class 10 witha double cut cycle and AGMA Class 9with a single cut cycle can be expected. The 100H weighs 7,100 lbs with acube size of 78” X 64” X 72” high.For more information, contactBourn & Koch at (815) 965-4013,6GEAR SOLUTIONS The Boeing F/A-18E/F Super HornetBoeing F/A-18E/F Super Hornet Completes First AESA FlightIn a press release dated August 13, 2003, it was announced that the Boeing F/A-18E/F SuperHornet program moved closer to equipping the fleet with the latest in radar technology on July 30 atNaval Air Systems Command China Lake, California, when a test aircraft carrying the APG-79 ActiveElectronically Scanned Array radar system completed several test flights with the radar operating.“We are continually increasing the capabilities that puts the ‘super’ in Super Hornet,” says NavalAir Systems Command F/A-18 Program Manager Capt. B.D. Gaddis. “This is a major step towardmaking the F/A-18 all that we’ve planned it to be.”The AESA radar system replaces existing mechanically scanned antennas with a radar beam thatcan be steered at close to the speed of light. This rapid beam scan feature improves performancedramatically, and because the array is solid state, mechanical breakdowns will be virtually eliminated.“The AESA radar system is part of a spiral development designed into the Super Hornet playingan important role in its promised leading-edge technology,” says Tony Parasida, vice president, F/A18 program, for Boeing. “The Super Hornet was designed with room for growth—room to incorporate new technologies now and to enhance the aircraft’s network centric capability.”AESA works with several existing elements of the Super Hornet weapon system, such as the storesmanagement system, the gun director, and AIM-120 and AIM-9 missiles, to enhance the lethality,survivability, and affordability of the F/A-18E/F. The radar system will increase situational awarenessof the battlespace and reduce observability of the aircraft, as well as provide significantly improvedoperational capability in a weapons platform that already provides superior air and ground attackmaneuverability and accuracy. Boeing expects to deliver the AESA radar system, built under a subcontract by Raytheon Corporation of El Segundo, California, as part of the F/A-18E/F by 2005.A unit of The Boeing Company, Integrated Defense Systems is one of the world’s largest spaceand defense businesses. Headquartered in St. Louis, Boeing Integrated Defense Systems is a 25 billion business. It provides systems solutions to its global military, government, and commercial customers. It is a leading provider of intelligence, surveillance, and reconnaissance; the world’slargest military aircraft manufacturer; the world’s largest satellite manufacturer and a leadingprovider of space-based communications; the primary systems integrator for U.S. missile defense;NASA’s largest contractor; and a global leader in launch services.For more information contact Kathleen M. Cook, Naval Systems, at (314) 233-6818, or via e-mailat kathleen.m.cook@boeing.com. Visit the company’s Web site at [www.boeing.com].OCTOBER 2003 gearsolutionsonline.com