Prices of Functional Fluids in 2013

The July 2010 issue of Gear Technology magazine had an article which reports that the demand for synthetic lubricant and functional fluid will reach around $4.8 billion by the year 2013. According to the article, this estimation would require a three percent raise in demand over the next three years to be correct. This means a lot for those in the market of lubricant distribution, but also serves as a prediction for those in the gear manufacturing industry. As the article reports regarding trends in industries related to function fluids:

"While engine oils and hydraulic and transmission fluids will achieve relatively strong growth going forward, other types of synthetic lubricants and fluids are expected to realize a slow decline in demand through 2013, largely as a result of falling average fluid prices. The largest market for synthetic lubricants and function fluids is light vehicles. This reflects not only consumer uptake of engine oils and transmission fluids, but also the universally synthetic nature of antifreeze, break and de-icing (windshield wiper) fluids."

It is clear from this article and other articles recently discussed in this blog that synthetic lubricants and functional fluids will play a large role in many industrial arenas over the next few years. As gear manufacturers, it is likely that our relationship to the fluid and lubrication market will change as a result of this. It is always a good idea to try to anticipate changes in your market before they effect your business, but this article stands as a shining example of how paying attention to related markets may hold some benefit in projecting the future of your market.

To read the article from Gear Technology Magazine, click the link below:

http://www.geartechnology.com/

AmCon Design and Manufacturing Expo 2011

It’s the season for industrial expos, and the gear manufacturing industry hasn’t been left behind. The AmCon Design & Manufacturing Expo is being held in Detroit, Michigan on November 8^th and 9^th at the Suburban Collection Showplace. From Forming and Fabrication to gear making and design, the AmCon Design and Manufacturing Expo offers you the opportunity to shake hands and talk shop with leaders from nearly every aspect of the manufacturing industry.

Attendee and exhibitor registration are still open for the event, and the value of the connections and networking contacts you can make could possibly help you propel your business to the next level. By meeting and establishing relationships with other businesses that work in your arena, you can increase the available services that your company offers and make your capabilities list more appealing to potential consumers. There’s no better place to accomplish this than at an expo, and the AmCon D&M Expo is the perfect opportunity to put yourself out there and potentially grow your business.

Let us know if you plan on attending the AmCon Design and Manufacturing Expo, or just share your opinion by sounding off in the comments section below!

Gearing up for Gear Expo 2011!

The Duke Energy Convention Center in Cincinatti, Ohio is going to be the place to be on November 1^st to the 3^rd if you’re in the gear-manufacturing arena. Over one-hundred distributors and manufacturers are converging to discuss every aspect of the gear industry – educational seminars discussing cutting processes, meet-and-greets with the big players in our market and even group discussions regarding customer relations will be offered.

You can find a full map and list of exhibitors on geartechnology.com to help you find your way through the incredible amount of booths that have been jam-packed into this year’s event. There’s a lot to say and a very limited time to see it all in, so we recommend taking a look at what’s happening when and where in order to plan where you’re going to be.

There are over 25 technical meeting presentations at Gear Expo 2011. While they are spread out over all three days of the event, if you plan on attending, it’s important to plan your time accordingly. There’s lots to see – but they’re well aware of this and have provided a detailed itinerary for your perusal on their website.

Let us know what exhibits you’re excited about at the Gear Expo 2011 by sounding off in the comments section below!

Keeping the next generation moving forward...

There's a nice story out of the News-Gazette of Champaign, IL about youth education in engineering. The South View Middle School is stepping up its science-technical educational efforts and it seems to be a hit with the students. While students get to work in groups, brainstorm, and develop their math-science skills, they also engage in hands-on learning.

Eighth-graders Andrew Nelson and Joby Means, who have been studying mechanical gears and how they are used, build a bevel gear with materials from a kit.

"This was easy," Joby said, turning a crank to make the gears move. Soon, students will learn how to move the gears using a computer program.

Like Jelicia and Ashylee, Andrew said he didn't know whether he would like the pre-engineering activities, which he started in sixth grade. But Smith's classes quickly became his favorite, and he's looking forward to continuing them in high school and college.

Even if not every student--likely--in the program goes on to an engineering degree, the school is definitely planting the seeds for the engineers of tomorrow.

Romans, Countryman, lend me your... Well, you know the rest...

Ford Motor Company looks to be doing something original with its research and development: It has designed and engineered an automatic transmission that will deliver better fuel economy to a car than a manual transmission would. The gain seems to be about 11%, presently. The company calls its new transmission technology PowerShift.

The dual dry-clutch PowerShift automatic transmission is based on efficient manual transmission technology, eliminating the additional weight and complexity of a torque converter, planetary gears and the fluid pumps employed in traditional automatics. Electronically controlled, twin internal clutches shift gears quickly and smoothly, providing a seamless flow of torque with the refinement and ease customers expect from a premium automatic transmission.

Ford will equip PowerShift in this year's Ford Fiesta. By the end of the year, it expects to have 85% of its automobiles with PowerShift capability. And by 2013, it hopes to offer PowerShift in all its vehicles.

PowerShift is an interesting technology. It's a dual-clutch in order to reap many of the benefits of manual transmissions. And using new technology, it results in better mileage. This is the sort of innovation that's been sorely lacking in American automobile design. We're frankly thrilled to see it developing--finally.

(Image Source: Wikimedia Commons)

A recent article from GearTechnology Magazine discusses the increase in consumption of manufactured technology in the United States, referred to as the USMTC or US Manufacturing Technology Consumption. The article states that according to the American Machine Tool Distributors' Association and the Association for Manufacturing Technology, May saw a consumption total of $178.34 million. The number was reached based on data supplied by companies that participate in the USMTC program, which, while showing a decrease from April of this year, is up almost sixty percent from May of 2009. The article quotes the president of the Association for Manufacturing Technology:

"While we would like to see the first quarter growth rates continue, we are not surprised by the typical second quarter ebb and flow in capital spending," says Peter Borden, AMTDA president. "We have seen an additional month of substantial orders, which helps to confirm that a sustainable recovery is taking place despite the buzz of those forecasting a W-shaped rebound. Industry forecasts for the year have been revised slightly upward by many sources, and if Congress passes the bonus depreciation allowance, this could accelerate growth even further."

The full report, which is available at www.amtonline.org, also contains a geographical breakdown of the Northeast, South, Midwest, Central and Western regions as they relate to this uptrend in manufacturing technology consumption. Essentially, this report is important to gear manufacturers because it could signal a boom in our industry that has already begun and may become more apparent by the end of the year. It would probably be a good idea, if you belong to this industry to read the full article.

Check out one of our top-rated sites at www.unitedvacuum.com for more information.

To learn more about Gear Manufacturing technologies visit GearMotions:

http://www.gearmotions.com/

To read the full report from amtonline, visit this link:

www.amtonline.org

To read the article from GearTechnology magazine:

http://www.geartechnology.com/news.php?in=2530

Manufacturing and the Mis-steps that go with it...

A new combined process machine by Gleason is setting the standard for multiple-function machines for gear manufacturers that require drilling, milling, chamfering/deburring, hobbing and turning all in a single operation. As modern gear manufacturers are aware, the industry is propelled forward by developing more intricate and complex gear designs that can handle larger loads with increased durability and efficiency. A machine like the AGILUS® 180TH represents the next generation of gear-manufacturing hardware, allowing several tasks to be completed in unison, saving the user time and resources.

An article on the new machine by Thomasnet News says of the AGILUS 180TH:

"As compared to typical production of cylindrical gears requiring hobbing, the AGILUS 180TH greatly reduces the number of machines, setups and overall through-put times for the complete processing of the gear, thus reducing both the capital investment and cost per workpiece for the user. AGILUS' ability to perform, in a single setup, complete machining of a wide range of shaft- and disc-type cylindrical gears also gives the user a greater degree of flexibility, higher machine availability, and optimized throughput as compared to the typical process where multiple single-purpose machines are used, requiring time-consuming changeover from part to part."

As the gear manufacturing industry continues to evolve, it is likely that machines with similar capabilities to the 180TH will continue to drive the evolution of the gear market. As lower batch sizes, increasingly complex gear applications and reduced inessential setup times become issues that relate to a business' bottom line, more gear manufacturers will be drawn to do-all machines like the AGILUS 180TH. Companies that work in large scale industrial settings, like vacuum pump part manufacturer United Vacuum will also get a boost from the reduced set up time as well. As gears become more complex, but smaller, supporting businesses that produce conducive products (such as vacuum pumps used in industrial workspaces) will continue to grow, leaving several opportunities for our industries to cross over (for everyone's benefit!). In the next few years, these machines will continue to be instrumental in the development of our industry, meaning more jobs for qualified operators, less money wasted on inefficient operations and more options for gear manufacturers and their clients.

Visit United Vacuum to learn more about setup time and issue resolution when working in an industrial environment! www.unitedvacuum.com

To read the article from Thomasnet News, click the link:

http://news.thomasnet.com/fullstory/Multifunction-System-offers-complete-cylindrical-gear-machining-574577

For more information on complex gear-machining processes, check out Gear Motions:

http://www.gearmotions.com/gearing-news/

AMT Reports Increased Consumption of Manufacturing Technology in June...

(Image courtesy of Kruse Kronicle)

A recent study by the Association for Manufacturing Technology (AMT) and the American Machine Tool Distributors' Association (AMTDA) has reported that the consumption of manufacturing technology processes is up nearly 36% from may and 71% from June of 2009. The gear manufacturing industry has been on a steady rise since our last article on the state of the manufacturing technology trends in America, meaning that those involved in gear manufacturing will have a lot more on their plate as we approach 2011. The data for the research was based on data reported by companies involved with the USMTC program. An article from geartechnology.com discusses the development:

"Typically, manufacturing technology order rates slow down in the months leading up to the International Manufacturing Technology Show-IMTS (Sept. 13-18, McCormick Place, Chicaco, IL), the largest production technology show in the Americas," said Douglas K. Woods, AMT president. "However, increased foreign direct investment and a doubling of orders in aerospace and construction equipment through the first half of 2010 resulted in an acceleration of USMTC order rather than the typical slow down."

As the demand for manufacturing technology continues to rise in the United States, it is likely that all of those involved in the gear manufacturing industry will have a steady stream of new clients and greater challenges on the horizon. For this reason, we at the Blog of a Gear Manufacturer, recommend paying attention to statistical changes in the manufacturing arena as soon as new information is available. By staying ahead of the curve, you are more likely to meet your customers expectation and surpass your business' capabilities.

To learn more about gear manufacturing, check out Gear Motions:

www.gearmotions.com

To read the article from geartechnology.com, click this link:

http://www.geartechnology.com/issues/0910x/industry.pdf

One of the Greatest Gear Making Tools - And it isn't What You Think!

(Image Source: Wikimedia Commons)

I found a really interesting article from around 2004 while puttering around Gear Solutions magazine's archives. It's about a "miracle tool" for producing parts from bar stock, such as gear blanks. You'd probably be really surprised (or, unsurprised, if you paid attention to the graphic at the beginning of this post) to hear that this miracle tool is the buzz saw. The author, Fritz Greulich, discusses the pros and cons of using a multiple cutting edge tool to manufacture gear parts, making note of how the stability, consistence and reliability of circular cutting tools have increased rapidly over the last few years. Here's an excerpt from the article:

"Not only is RSC a viable reality, it is also far superior to single point tooling in its capabilities. The multiple cutting edges of a circular saw eliminate the problems of high heat buildup, undesirable chip formation, and high chip load. The result is a myriad of technical advantages that increase production levels, improve quality, and lower production costs: more parts per hour, more parts per bar, better finishes, increased tool life, easier and less costly scrap handling, and increased machining capabilities. A rotating circular saw cutting through a rotating bar of stock builds up very little heat for a number of reasons. First, saws are ground with side clearance. Clearance reduces the friction between the workpiece and the cutter. Second, cutting with a rotating circular saw is an "interrupted" cut, since each tooth cuts for only a brief moment. Third, as a single saw tooth makes a cut, the chip (and heat) is immediately removed from the cutter by the strong coolant flow and the centrifugal force of the rotating saw. Finally, each cutting edge is removing only a small amount of material, keeping the chip load low."

So, what benefit does this article hold for those of us in the gear manufacturing industry? Most notably that with all of the recent advances in our engineering technology and the big expo coming up, it may be easy to only look toward the future for ways to improve our efficiency - but we also shouldn't forget the past. Articles like this one that promote ingenuity and thinking outside the box should be heralded for their ability to take a process that many think has been "perfected" and apply a new twist to it that increases quality, decreases waste and eventually will augment profit.

To learn more about the latest in gear manufacturing, visit Gear Motions:

www.gearmotions.com

To read the article from Gear Solutions Online, follow this link:

http://www.gearsolutions.com/article/detail/5622/a-super-tool-for-superior-gear-blanks

Excellence in Gear Manufacturing and the Future of the Industry

With IMTS 2010 getting closer and closer with every passing second, the gear manufacturing industry is abuzz with what will be "the next big thing". But, an article on enterprise excellence from geartechnology.com suggests that "the next big thing" might just be a different way of looking at how we in our industry do business. Things like breakdowns in communication, late delivery schedules and component available all contribute to efficiency losses in the gear manufacturing market. So what is enterprise efficiency? The article from geartechnology.com explains it this way:

"In a sense, the idea of enterprise excellence should involve a different mindset; it should transition beyond defect reduction to one of performance improvement. Its approach should be to capitalize on past successes and collectively focus on organization on its strengths. Then a company is equipped and flexible to address problems, capture opportunities, adapt to changing requirements and technologies, and evaluate associated risks."

It's likely that instead of a new technology emerging or a new type of gear being developed, that the next big evolution in the gear technology field will be our ability to anticipate and compensate for errors in different parts of the process. In the future, when new materials are discovered and processes change, it would be a good idea to have a system in place to assist in these transitions. This is likely that "next big thing" that everyone's waiting for.

To learn more about gear manufacturing, check out Gear Motions:

www.gearmotions.com

And to read the article from geartechnology.com, go here:

http://www.geartechnology.com/issues/0910x/voices.pdf

Significant Advances in Single-Pass Finishing for Gear Manufacturers

(Image Courtesy of The Energy Collective)

New techniques are opening up to those in our industry thanks to a new approach to the single-pass finishing process as it relates to the manufacturing of gears. An article in Gear Solutions magazine discusses some of the changes that have been implemented, and the potential advantages of this recently discovered technology. Diamond tooling can be expensive - the cost of materials and the upkeep of your equipment can seem taxing. The key to the single-pass process, as reported by Gear Solutions, involves following the existing centerline of the bore to be finished with as little pressure as possible. This ‘path of least resistance’ may seem like an obvious avenue of approach for many gear manufacturers- but there are many in our industry who have lost time and money on something so simple. The article relates the information in this way:

“The key to the single-pass process is to allow the diamond tooling to follow the existing centerline of the bore to be finished with as little pressure as possible. This is normally done by allowing the tool, part, or both to float. Depending on many other variables, bore geometry to better than 0.2µm (.000008”) is possible. Sine all of the diamond tools are set to specifice sizes and do not require expansion during each cyle, the single-pass process is able to achieve unsurpassed size control in production (1 µm with near perfect repeatability). These results are very predictable and repeatable, thus lend perfectly to Statistical Process Control.”

It seems like a no-brainer that this process would be successful, but by constantly trying to augment tools, assembly fixtures and machine augmentations, gear manufacturers have been able to steadily increase their production rates while improving the precision with which they bore. According to the article- fuel pumps, power-steering pumps, hydraulic timing components, connecting rods, cylindrical bores, diesel rollers and most importantly, gears can all benefit from these newly developed approaches to the single bore process.

To learn more about advances in gear manufacturing technology, check out Gear Motions:

www.gearmotions.com

To read the article from Gear Solutions Magazine, follow this link:

http://www.gearsolutions.com/article/detail/5459/advances-in-single-pass-bore-finishing

Pete and Repeat Build a Gear: Whose Client Calls Them Back?

Geartechnology.com has an interesting article this month regarding the recent economic downturn as it relates to gear manufacturers, and how those in our industry can meet and exceed our buyer's expectations with greater efficiency. The article, by associate editor Matthew Jaster, discusses the future of the gear manufacturing industry and what aspects of the business will come to the forefront as America begins to climb its way back from the recent recession. Among the areas of focus listed were quality of gears produced, the timeliness in which they are delivered to consumers, and the value of the actual product as it relates to customer satisfaction. According to the article, with more potential buyers shopping around for better deals and with less repeat business due to the recession, gear manufacturers should take heed to make sure that the people that come to them keep coming back:

"Customer service plays a large role in delivery as well. The medical manufacturing rep has received countless phone calls from customer service agents in the gear industry. "They just state the same thing over and over again. 'We'll have it in another three weeks,' 'Give us three more weeks,' 'It's going to be about three more weeks.' Sure, they were polite enough to keep us informed on where the order stood, but this wasn't exactly the kind of customer service we were looking for."

Warren Buffet, investment guru and philanthropist, summed it up when saying, "Price is what you pay; value is what you get." Whether your'e purchasing automobiles, heavy industrial equipment or a bulk order of gears, the same rules apply. The gear industry remains an area of manufacturing where complex components need to perform consistently and without failure. In the gear industry, companies tend to pay for what they get."

The article makes several solid points regarding the future of the gear manufacturing industry, particularly as it relates to producer/consumer relationships. Customer service is mentioned often as the main reason that customers may not come back to a manufacturer. For those of us in the gear manufacturing industry, the lesson we should take from this article is that customer support can sometimes have more of an effect on our business than the quality of the gears we produce. For next quarter, manufacturers should focus more on their bedside manner if they want to keep their clients coming back.

To learn more about the gear manufacturing process, check out Gear Motions:

http://www.gearmotions.com/

To read the article from geartechnology.com, follow this link:

http://www.geartechnology.com/issues/0810x/gearbuyers.pdf

Are you Ready for IMTS 2010?

At this years Industry and Technology Conference in Chicago, there will be over fifty gear manufacturers putting on exhibitions regarding the latest technology in the industry. They’ll also be there to rub elbows with fellow gear producers and discuss upcoming changes in the market (some of which have been detailed in previous posts on this blog). So, if you’re one of the many who were not able to get a spot in the Gear Technology pavilion and haven’t planned ahead on attending, what can the 2010 Industry and Technology Conference do for you? Gear Technology Magazine, who ran an article about the conference in this month’s issue, had this to say for non-attendees:

“It may take months of preparation to get the most out of the IMTS experience, and both exhibitors and the show management have abundant Internet resources available in advance. One such resource is through social networks online. IMTS insider news can be found on Facebook, Twitter and LinkedIn, as well as the IMTS technology e-newsletter. The IMTS group on YouTube features 60-second ehibitor submissions about why visitors should come to their booths. Visitors can vote to rate the video, and the highest rated one will have theirs posted prominently on imts.com.”

So, even if you can’t make the show itself, you can still get the gist of what each exhibitor will be discussing at their individual booths. Beyond that, each of the videos links to the exhibitors homepage, where you generally find a more developed discussion of the points made in their youtube videos. You also have the opportunity to decide which ones are the most relevant to gear manufacturing as an industry. The more manufacturers that vote for certain videos, the more likely it is that it will show as an indicator of how the industry is trending once the selected videos are permanently posted. So, even if you can’t make the show, you can at least swing over to their youtube channel and voice your opinion regarding what’s important in the gear manufacturing industry.

To learn more about Gear Manufacturing, check out Gear Motions:

www.gearmotions.com

To submit a video for the youtube competition, click on the IMTS website:

www.imts.com/60seconds

To read the article from Gear Technology magazine, click here:

http://www.geartechnology.com/issues/0810x/imts2010.pdf

Manufacturing Technology Consumption on the Rise...

(Image Source: Wikimedia Commons)

A recent article from GearTechnology Magazine discusses the increase in consumption of manufactured technology in the United States, referred to as the USMTC or US Manufacturing Technology Consumption. The article states that according to the American Machine Tool Distributors' Association and the Association for Manufacturing Technology, May saw a consumption total of $178.34 million. The number was reached based on data supplied by companies that participate in the USMTC program, which, while showing a decrease from April of this year, is up almost sixty percent from May of 2009. The article quotes the president of the Association for Manufacturing Technology:

"While we would like to see the first quarter growth rates continue, we are not surprised by the typical second quarter ebb and flow in capital spending," says Peter Borden, AMTDA president. "We have seen an additional month of substantial orders, which helps to confirm that a sustainable recovery is taking place despite the buzz of those forecasting a W-shaped rebound. Industry forecasts for the year have been revised slightly upward by many sources, and if Congress passes the bonus depreciation allowance, this could accelerate growth even further."

The full report, which is available at www.amtonline.org, also contains a geographical breakdown of the Northeast, South, Midwest, Central and Western regions as they relate to this uptrend in manufacturing technology consumption. Essentially, this report is important to gear manufacturers because it could signal a boom in our industry that has already begun and may become more apparent by the end of the year. It would probably be a good idea, if you belong to this industry to read the full article.

To learn more about Gear Manufacturing technologies visit GearMotions:

http://www.gearmotions.com/

To read the full report from amtonline, visit this link:

www.amtonline.org

To read the article from GearTechnology magazine:

http://www.geartechnology.com/news.php?in=2530

The Race to $5 Billion: Functional Fluids in 2013

(Image Source: ExxonMobil.com)

One of our recent blog posts dealt with the likelihood of a breakdown in an assembly being related to insufficient or incorrect lubrication. The July 2010 issue of Gear Technology magazine had an article which reports that the demand for synthetic lubricant and functional fluid will reach around $4.8 billion by the year 2013. According to the article, this estimation would require a three percent raise in demand over the next three years to be correct. This means a lot for those in the market of lubricant distribution, but also serves as a prediction for those in the gear manufacturing industry. As the article reports regarding trends in industries related to function fluids:

"While engine oils and hydraulic and transmission fluids will achieve relatively strong growth going forward, other types of synthetic lubricants and fluids are expected to realize a slow decline in demand through 2013, largely as a result of falling average fluid prices. The largest market for synthetic lubricants and function fluids is light vehicles. This reflects not only consumer uptake of engine oils and transmission fluids, but also the universally synthetic nature of antifreeze, break and de-icing (windshield wiper) fluids."

It is clear from this article and other articles recently discussed in this blog that synthetic lubricants and functional fluids will play a large role in many industrial arenas over the next few years. As gear manufacturers, it is likely that our relationship to the fluid and lubrication market will change as a result of this. It is always a good idea to try to anticipate changes in your market before they effect your business, but this article stands as a shining example of how paying attention to related markets may hold some benefit in projecting the future of your market.

To read the article form Gear Technology Magazine:

http://www.geartechnology.com/

Measuring Roughness and Surface Finish in Gears...

(Image Source: vibanalysis.co.uk)

If, like me, you read Gear Solutions magazine regularly, then you probably have read the "Tooth Tips" section before, and are probably aware of how smart of a guy William Crosher is. The reason I like his articles is because he doesn't dumb down the language for non-engineers. If you want to follow his articles, you have to be part of the industry, and that's just fine by me. The recent issue of Gear Solutions' "Tooth Tips" article is about the importance of roughness and surface finish as they relate to the longevity and effectiveness of a gear assembly. Without getting into great detail (he does, you can read the article if you want to get the full scoop), his basic point, in his own words, is as follows:

"There is no relationship between gear quality and surface finish in AGMA standards. An AGMA document on gear tooth surface texture (AGMA906A94) is a guide to surface finish. Unfortunately, there are still many who do not realize the significance of the surface finish on tooth flanks and believe -quite incorrectly- that it will be a self-correcting condition. Tests have indicated that the rubbing of any two surfaces reduces the initial roughness by no more than 25 percent."

Another point Crosher makes is that in order to achieve more accurate results, one must be aware of the "cutoff". There are several types of gears that have surfaces with many deep valleys, and its important to remember that flank surfaces should be measured in one direction, going from the tip to the root. Crosher's article is important because it discusses the need for standardization of further processes by AGMA while giving logical assessments of the importance of measuring roughness and surface finish. I always like an article that can make a process more efficient - they always end up saving me money.

To read Crosher's article, click here:

http://gearsolutions.com/article/detail/6001/title/william-crosher-tooth-tips

To find out more about recent developments in gear manufacturing technology, check out Gear Motions:

http://www.gearmotions.com/capabilities/ground-gears.php

Turning Bearing Failure into Bearing Success

(Image courtesy of toyotaoffroad.com)

There's an interesting article in Gear Solutions magazine this month regarding the identification and analysis of failed bearings. The article discusses how important it is for engineers to dissect bearings that have failed prematurely on a visual level, as well as taking the time to fix the causes of the failure as opposed to trying to re-invent their whole process. It is common in the gear industry for someone to say "Well, this bearing arrangement didn't withstand the amount of stress it was supposed to, we either need to implement a new set-up or at least the same process with a new material." The article discusses the problems and causes thusly:

"Most bearing failures such as flaking and pitting, spalling unusual wear patterns, rust and corrosion, creeping, skewing and others are usually attributed to a relatively small group of causes that are often inter-related and correctable. These causes include lubrication, mounting, operational stress, bearing selection, and environmental influence."

The article then gives a breakdown of the likelihood of each of the causes of bearing failure. Lubrication issues, including unsuitable, insufficient or aged lubricant, total fifty-five percent of bearing failures. Around thirty percent of failures were attributed to solid and liquid contamination, leaving only fifteen percent for errors such as "wrong bearing chosen" or "errors while mounting". Using these statistics, one can see that the majority of bearing failures are the result of miscalculations regarding lubrication, whereas only 1/3 of failures are due to standard wear and tear, and less than 1/5 of failures are the result of incorrect bearing selection or implementation. Keep these figures in mind the next time one of your bearings fails, you might save yourself some money by fixing something as simple as lubricant distribution, rather than replacing an entire arrangement.

To read the article from Gear Solutions magazine, you can download the entire issue from the link below:

http://gearsolutions.com/magazine/currentIssue

Gear Expo 2011 - Why You Should Go

The Duke Energy Center, home to this years Gear Expo

Every year, manufacturers and engineers from all across our industry get together to discuss the latest trends, technologies and strategies that are helping the evolution of the gear industry. The expo will run from November 1st to the 3rd at the Duke Energy Center in Cincinatti, Ohio. While registration for exhibitors and attendees are currently restricted, it is of interest that the website of the expo went live last week at www.gearexpo.com.

The article lists several powerful reasons for attending, the most notable being:

1. Make a more educated purchasing decision - Your sales reps can't travel around the country with their heavy machinery, so Gear Expo is your best opportunity to see the equipment in person before you make a large acquisition. You'll easily make up the time out of the office by holding a year's worth of business meetings in just three short days.

2. Stay ahead of the business cycle - Gear Expo only happens once every two years, you can't afford to miss it or you will be left behind as the industry moves forward.

3. Take a trip around the world of gearing all under one roof - Exhibitors and attendees travel from 30 countries and 30 states to meet at Gear Expo. Hear what's working across town or around the globe, and learn from your peers who stand in your shoes everyday.

4. Get out of your office or plant and discover your next "big idea" - Engineers, managers, and executives often spend too much time in an office. Don't miss the innovation that will drive your company and careers forward.

This list from the website covers the main reasons you'd want to go, but it does omit one large important benefit of attendance: Networking. The connections you make at an expo like Gear Expo 2011 can help propel your business to the front of the line in the gear manufacturing game. By establishing relationships with others in your field, you can decrease your own costs, find opportunities to work in tandem with other manufacturers and improve the overall efficiency of not only your institution, but the industry as a whole. So, plan to take the first three days of November off and come down to Gear Expo 2011!

New Combined Process Machine out of Rochester, NY

Image courtesy of Gleason.com

A new combined process machine by Gleason is setting the standard for multiple-function machines for gear manufacturers that require drilling, milling, chamfering/deburring, hobbing and turning all in a single operation. As modern gear manufacturers are aware, the industry is propelled forward by developing more intricate and complex gear designs that can handle larger loads with increased durability and efficiency. A machine like the AGILUS® 180TH represents the next generation of gear-manufacturing hardware, allowing several tasks to be completed in unison, saving the user time and resources.

An article on the new machine by Thomasnet News says of the AGILUS 180TH:

"As compared to typical production of cylindrical gears requiring hobbing, the AGILUS 180TH greatly reduces the number of machines, setups and overall through-put times for the complete processing of the gear, thus reducing both the capital investment and cost per workpiece for the user. AGILUS' ability to perform, in a single setup, complete machining of a wide range of shaft- and disc-type cylindrical gears also gives the user a greater degree of flexibility, higher machine availability, and optimized throughput as compared to the typical process where multiple single-purpose machines are used, requiring time-consuming changeover from part to part."

As the gear manufacturing industry continues to evolve, it is likely that machines with similar capabilities to the 180TH will continue to drive the evolution of the gear market. As lower batch sizes, increasingly complex gear applications and reduced inessential setup times become issues that relate to a business' bottom line, more gear manufacturers will be drawn to do-all machines like the AGILUS 180TH. In the next few years, these machines will continue to be instrumental in the development of our industry, meaning more jobs for qualified operators, less money wasted on inefficient operations and more options for gear manufacturers and their clients.

To read the article from Thomasnet News, click the link:

http://news.thomasnet.com/fullstory/Multifunction-System-offers-complete-cylindrical-gear-machining-574577

For more information on complex gear-machining processes, check out Gear Motions:

http://www.gearmotions.com/gearing-news/

Winds Continue to Blow in the Favor of Gear Manufacturers...

(Image Courtesy of the Site Selection Energy Report at siteselection.com)

Several of our more recent posts have dealt with developments in gear manufacturing as it relates to renewable energy, most notably in the field of wind energy. It is likely that these two technologies will continue to walk hand-in-hand into the future in which both industries will develop a symbiotic relationship. The Windpower 2010 conference was recently held in Dallas, Texas where several burgeoning new technologies were revealed, and the importance of the evolution of gear technology was evident in the demonstrations that were displayed. Of particular interest is the development of a new lubricant from Kluber Lubrications which can handle the varying lubrication requirements of individual bearing applications within a wind power station. As is quoted in the article from Gear Technology Magazine:

"The Klüberplex BEM 41-141 is a beige grease that features a special blend of base oil and additives to cover the varying lubrication requirements of the individual bearing applications within wind power stations. These include pitch and yaw bearings (high stresses, oscillations, vibrations), main bearings (low rpm, high stresses, vibrations), and generator bearings (high rpm and temperatures). Also on display was the Klüberplex AG 11-462, which is a gear grease that provides adhesion and protection against high loads and corrosion. The white grease lubricates the control gears for pitch and yaw systems while reducing the risk of migration inside the nacelle and onto the tower."

These new developments in lubrication technology will serve as a huge boon to the gear manufacturing industry, in which the varying thresholds and strength requirements for individual applications can sometimes lead to inaccurate calculations regarding the amount of stress a material will have to withstand. By anticipating developments in complimentary technologies, gear manufacturers will be able to assess strength requirements with improved accuracy, as adapting lubricants will allow them to cover a broader spectrum of applications. In an era where gear and wind power technologies are rapidly advancing alongside each other, it is always good news to hear about a new process which can allow all parties involve to achieve their goals in a more fluid manner.

To read the article from Gear Technology Magazine, follow the link:

http://www.geartechnology.com/issues/0610x/windpower.pdf