Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
No. 940 is a gas-fired 500°F (~260°C) walk-in oven from Grieve, currently used for curing brake friction materials at the customer’s facility. Workspace dimensions are 72” wide x 96” deep x 78” high. 400,000 BTU/HR are installed in a modulating natural gas burner inside the oven, while 700,000 BTU/HR are installed in a modulating natural gas afterburner. The oven’s initial exhaust passes through the 1400ºF afterburner. A 6000 CFM, 5-HP recirculating blower provides combination airflow to the workload.
The oven has 4” thick insulated walls, aluminized steel interior and exterior, plus a top-mounted heating chamber. All safety equipment required by IRI, FM and NFPA Standard 96 for gas-heated equipment is onboard, including a 650 CFM, ½-HP powered forced exhauster.
Controls on No. 872 include digital indicating temperature controllers and a 10” diameter circular chart recorder.
For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, IL 60073-2898
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese, VP
FOREST CITY GEAR EXPANDS BLANKING DEPARTMENT
Leading gear manufacturer acquires three new Haas turning centers to produce “donuts” for its gearmaking operations
Forest City Gear’s blanking department now boasts a Haas ST-10 and two ST-20 Turning Centers. These machines were acquired recently to improve the throughput at Forest City Gear, a world leader in fine- and medium-pitch gear and spline work. The machines are used primarily for production of “donuts”, the near net blanks used in the company’s gearmaking operations.
Roscoe, IL-Forest City Gear has acquired three Haas turning centers to improve the throughput at its gearmaking facility. The company has made this investment, according to President Wendy Young, “…because we needed to better control our throughput and reduce the time to start up jobs. We were experiencing some severe delays from outside vendors and we saw problems on the horizon from such bottlenecks. Our company is always on the lookout for such conditions, because both our quality and our delivery protocols are vital to our success with current and potential customers in the world market.” These new machines will be used in the company’s Blanking Department, headed by Tommy Kalt, who detailed the new machines.
“We purchased a Haas ST-10 Turning Center with a magazine bar feeder, 300 PSI high-pressure coolant system and automatic tool presetter. It’s a fast, very flexible and very easy-to-use machine tool.” This machine, as well as two Haas ST-20 Turning Centers with 8” chuck and 20-station hybrid turret, fully programmable tailstock and high-pressure coolant pump, are currently operating in the Forest City Gear facility to produce “donuts” from automatically fed bar stock. These donuts are the near net shape blanks used in the gearmaking operation here. As a custom producer of extremely tight tolerance gears for the most demanding applications, according to company CEO Fred Young, “We need to have optimum control of our operation, at every step. Our company today exports gears to every corner of the world and our rigorous quality standards require a number of intermediate steps, prior to shipment. If the blanks are not available and our production is delayed, the entire operation slows and we simply will not allow that to happen,” Young stated emphatically.
Kalt expands on the ST-10. “It has a manual, programmable tailstock for shaft work, another real advantage in 
our type of shop, where we do a lot of splines in addition to gears. Plus, the Haas CNC system is very easy to learn and to use. It has simple language commands and most operations can be done with the push of a button. I like to say it has an American-made feel to it. The work area is open, the tooling is easy to change and the learning curve was really short for our guys. They were up and making good parts almost immediately.” He noted that the performance of the first machine led quickly to the purchase of the two additional Haas ST-20 turning machines. Kalt also cited the ECO CNC system on the Haas machines, with minimal lubrication requirements and auto-power down features were in sync with the Forest City Gear green initiative programs, as a further value to this purchase.
On the business side, Wendy Young was very satisfied with the cooperation of the Haas sales and delivery team. “We were treated fairly and the support has been first-rate, right from the start. We already see the benefits of this purchase to our company.”
For more information on this story, please contact: FOREST CITY GEAR CO., INC. 11715 Main Street Roscoe, IL 61073-0080 Phone: 815-623-2168 Fax: 815-623-6620 Web: www.forestcitygear.com
Email: wyoung@forestcitygear.com Attention: Wendy Young, President
PR agency contact for Forest City Gear: Tim Daro Bernard & Company 847-934-4500 tdaro@bernardandcompany.com
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Hennig, Inc., Machesney Park, Ill., announces the opening of an additional facility on its 11-acre campus here, to accommodate the expanding power gen business of Hennig Enclosure Systems. This new facility is now open and houses all design, engineering, sales, marketing and manufacturing capabilities for this division of Hennig, a world leader in machine protection. Utilizing additional land area outside the new facility, Hennig will also be able to test all enclosure and fuel tank systems under full operating conditions for its customers. Load bank testing, resistance testing, airflow performance and sound level checks can all be performed in an actual outdoor environment.
In announcing this new facility, Robin Moore, Vice President of Engineering and Operations for the company, commented, “Our power gen business is ramping up substantially and we required expanded capabilities, additional staff and more capacity.” He also noted the larger work bays and four overhead cranes (two tandem 7.5 ton and two tandem 20 ton with max. 80,000-lb. lift) will complement the tank welding process, electrical assembly, enclosure assembly and a new in-house finishing department for wet paint and powder coating at this Hennig facility. The new location is conveniently located off Interstate I-90 at the recently completed Route 173 interchange for easy on/off logistics, a decided advantage in transporting the huge structures produced here.
At this new location, Hennig Enclosure Systems will produce turnkey enclosures and fuel tanks for OEM power generator customers, as well as architects, design/build firms, contractors and consulting/engineering companies who constitute its current customer base. Customers interact with the company by utilizing the network of Hennig field sales engineers and service centers, as well as the recently developed online configurator software at the company’s website.
Greg Champion, Vice President of Sales and Marketing, further noted, “Our customers will quickly benefit from the improvement in work flow and logistics provided by this new facility. Being immediately adjacent to the Hennig Global Headquarters will have many upsides for our customers and us alike.” Champion further noted Hennig now has 150 employees onsite at this combined facility, for a total of 450 worldwide.
Local Rockford, IL contractor Cord Construction completed this new facility in less than six months from the date the previous facility was acquired by Hennig in November, 2010.
Hennig Enclosure Systems will further offer a limited amount of indoor generator storage for customers at the new facility to provide additional benefit.
In addition to its work in the power generator market, Hennig, Inc. designs and produces custom machine protection and chip/coolant management products for state-of-the-art machine tools. Hennig products are designed to protect against corrosion, debris and common workplace contaminants. Manufacturing facilities are located in the U.S., Germany, France, Brazil, India, Japan, China and South Korea. Repair centers are located in Machesney Park, IL; Chandler, OK; Livonia, MI; Blue Ash, OH; Mexico City, Mexico; and Saltillo, Mexico.
To learn more about Hennig Enclosure Systems, visit www.hennig-enclosure-systems.com or contact:
Tim Waterman
Hennig Inc.
9900 N. Alpine Rd.
Machesney Park, IL 61115
(815) 316-5277
info@hennig.ame.com
www.hennigworldwide.com
Connect with Hennig online: 
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Hennig, Inc. designs and produces custom machine protection and chip/coolant management products for state-of-the-art machine tools. Hennig products are designed to protect against corrosion, debris and common workplace contaminants. Manufacturing facilities located in the USA, Germany, France, Brazil, India, Japan, Czech Republic, England and South Korea. Repair centers are located in Machesney Park, IL; Chandler, OK; Livonia, MI; Blue Ash, OH; Mexico City, Mexico; and Saltillo, Mexico.
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No. 905 is an electrically-heated 1200°F(~648.89°C) high temperature walk-in oven from Grieve, currently used for heat treating. 120 KW are installed in Incoloy sheathed tubular heating elements. Workspace dimensions are 48” wide x 180” deep x 72” high.
The oven has 10” thick insulated walls comprised of 2” of 1900°F block and 8” of 10 lb/cf density rockwool, an aluminized steel exterior and a Type 304, 2B finish stainless steel interior. A 12,500 CFM, 10-HP recirculating blower provides universal front to rear airflow to the unit.
The unit is also equipped with a 7” insulated floor with truck wheel guide tracks and a flatbed loading truck with a 5000 lb capacity. The external frame works with lifting eyes to allow this 18,000 lb oven to be moved by crane. It also features inner and outer gaskets; the inner gasket seals directly against the door plug and the outer gasket seals directly against the front face of the oven.
Controls onboard No. 905 include a digital programming temperature controller, free standing remote control panel, manual reset excess temperature controller with separate contactors, SCR power controller, strip chart recorder and recirculating blower airflow safety switch.
For more information, please contact: THE GRIEVE CORPORATION, 500 Hart
Road, Round Lake, Illinois 60073-2835 USA. Phone: (847) 546-8225. Fax: (847) 546-9210. Web: www.grievecorp.com. Email: sales@grievecorp.com. Attention: Frank Calabrese.
Agency Contact: Tim Daro: 847-934-4500
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The process orientation of MAGMA5 illustrated using die casting
During the upcoming GIFA 2011 show in Dusseldorf, Germany, Magma will present its new software generation for casting process simulation, MAGMA5. At the 300 sq. m stand 12A16, the company will demonstrate how casting process simulation with MAGMA5 can be used for optimization at all stages of casting manufacturing to contribute to foundry profitability. MAGMA will show the newest version MAGMA5 5.2 with extended capabilities for all cast materials and processes, introduce its new software MAGMA C+M for the simulation of the core production processes and provide a view into the future of autonomous optimization of casting processes. Additionally, MAGMA is participating in the initiative “ecoMetals” from the Messe Düsseldorf, which supports companies who develop innovative products and processes leading to a more efficient use of energy. MAGMA will demonstrate, using practical examples, how the application of casting process simulation considerably increases a foundry’s energy and resource efficiency.
MAGMA5 – optimized simulation
Autonomous optimization of casting processes and layouts, shown here for gating optimization in die casting, is the future of casting processsimulation.
MAGMA5 5.2 introduces several new simulation capabilities: new process modes for permanent mold, low pressure sand and low pressure die casting, as well both hot-chamber and cold-chamber die casting, allow for detailed process-specific definitions. The software also supports process design by controlling process parameters during a simulation run. For gravity casters, process modules for DISAMATIC and investment casting are now available.
At GIFA, MAGMA will also present its newest developments for the quantitative prediction of as-cast and heat treated local microstructures and properties in aluminum, iron and steel castings. MAGMA5 simulates sand and reoxidation inclusions during mold filling and predicts defects related to molding materials. MAGMAnonferrous calculates the final microstructure and mechanical properties for aluminum alloys considering the metallurgy, inoculation, and hydrogen content of the melt. MAGMAiron predicts local microstructures for iron materials from graphite growth through to the distribution of phases making up the matrix. MAGMAsteel calculates macrosegregation in steel castings and the local microstructure resulting from heat treatment.
The stress module MAGMAstress for the first time offers casters the option to calculate thermally induced casting stresses in permanent molds for all manufacturing steps, including heat treatment and finishing, in order to predict casting crack problems and distortion. The simulated distortion results can be evaluated just as on a coordinate measuring machine and compared directly with real measurements. For the first time, the new module MAGMAdielife facilitates the evaluation of the effects of tooling design and thermal stresses on the durability of permanent molds.
MAGMA Core+Mold – transparency in core production
With MAGMA C+M, the simulation of the core shooting process is possible for complex tools, shown here for three cores including blow tubes in a single core box.
With MAGMA C+M, MAGMA introduces an integrated tool for the simulation of core production processes. MAGMA C+M simulates core shooting, blowing and hardening of organic and inorganic cores. Processes where binder hardening is driven by a catalyst gas as well
as core production with tempered core boxes are supported. MAGMA C+M considers all aspects of core production starting from the core shooter, in order to calculate the flow of the air-sand mixture based on the real shot parameters. An integrated database provides the ability to specify the characteristics of the sand and the binder system as well as core box vents and blow tubes. The program simulates gassing, purging and the curing reaction of gas-hardened cores. The design and control of core box tempering for heat-cured cores (hotbox, croning, inorganic) is effectively supported by modeling of heating cartridges and oil channels. For inorganic cores, MAGMA C+M calculates the drying of the core in the heated core box as well as due to transport of water vapor by hot air during gassing. MAGMA C+M takes advantage of all the functionality of MAGMA5 and is available as an add-on module to MAGMA5 or asa stand-alone product.
Autonomous optimization is the future
With autonomous optimization, foundrymen can make use of simulation in order to pursue their objectives for quality and cost. Autonomous optimization makes proposals for the right casting layout or the optimum process parameters. The virtual test foundry in the computer enables variation of parameters and systematic examination of influencing variables leading up to the optimum configuration. Based on the fundamental physics embedded in MAGMA5, the program finds the best possible dimensions and positions of ingates, as well as the location of feeders and chills including their optimum size. Using industrial examples, MAGMA will present state-of-the-art capabilities and provide a view into the future of optimization.
MAGMA – very involved
At the accompanying WFO Technical Forum, MAGMA will give presentations on the topics of aluminum casting, core production, and optimization. At the NewCast exhibition, which takes place in parallel with GIFA, simulation specialists will discuss the prediction of residual stresses and distortion in cast iron components.
MAGMA also has a further exhibition stand (12A15) as part of the “Get-In-Form” project “Youth-Technology-Future” (“Jugend-Technik-Zukunft“). Here, the attractiveness of work as a professional or specialist in the metal casting industry will be illustrated to students and apprentices in an entertaining and interactive manner.
About software for casting process simulation
Casting process simulation software considers the complete casting process including mold filling, solidification and cooling, and also provides the quantitative prediction of mechanical properties, thermally induced casting stresses and the distortion of cast components. Simulation accurately describes a cast component’s quality upfront before production starts, thus the casting layout can be designed with respect to the required component properties. This results in a reduction in pre-production sampling, but also the precise layout of the complete casting system leads to energy, material and tooling savings for the foundry.
The range of application of MAGMA solutions comprises all cast alloys, from cast iron to aluminum sand casting, permanent mold and die casting up to large steel castings. The software supports the user in component design, the determination of melting practice and casting methodology through to mold making, heat treatment and finishing. This saves costs consequently along the entire casting manufacturing line.
During the last 10 years, the use of casting process simulation has become a valuable business asset for many foundries. MAGMA5 now expands the capabilities of casting process simulation and will further accelerate the acceptance of this technology.
About MAGMA
MAGMA offers comprehensive solutions to the metal casting industry, casting buyers and casting designers worldwide. The MAGMA product and service portfolio includes the powerful modular simulation software MAGMASOFT®,with the newest release MAGMA5, as well as engineering services for casting design and optimization.
Today, MAGMASOFT® is used throughout the metal casting industry, especially for the optimization of cast components in automotive and heavy industry applications.
MAGMA Giessereitechnologie GmbH was founded in 1988 and is headquartered in Aachen, Germany. A global presence and support are guaranteed by offices and subsidiaries in the USA, Singapore, Brazil, Korea, Turkey, India and China. Additionally, more than 30 qualified partners represent MAGMA around the world.
For more information on this release, please contact:
Christof Heisser President MAGMA Foundry Technologies, Inc. 10 N. Martingale Road, Suite 425 Schaumburg, IL 60173 Phone 847-969-1001 ext. 225
Email: cheisser@magmasoft.com Web: www.magmasoft.com
Agency contact: Tim Daro Bernard & Company 847-934-4500 tdaro@bernardandcompany.com
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No. 874 is an electrically-heated 650°F(~343.3°C) indexing chain conveyor oven from Grieve, currently used for processing pallets of PVC parts on mandrels. 40 KW are installed in Incoloy sheathed tubular heating elements. Workspace dimensions are 42” wide x 84” deep x 15” high.
The oven has 5” insulated walls and an aluminized steel interior and exterior. It features three zones: 2’ long open belt loading zone, 7’ long insulated heat zone with recirculated airflow and 4’ long open unloading zone. The mandrels holding product move through the oven on two strands of 60 pitch roller chain on 35” centers, powered by a ¼ HP motor drive with fixed speed of 32 inches per minute.
A 4200 CFM, 3-HP recirculating blower provides vertical downward airflow to the workload, while a 325 CFM powered forced exhauster is also onboard. Motor operated vertical lift doors are provided at each end of the oven.
Controls onboard No. 874 include SCR power controller and fused disconnect switch. A PLC controls temperature and conveyor indexing.
For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, IL 60073-2898
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese, VP
SAM 600G machine being introduced to the foundry market at open house, to be held at Hunter Automated near Chicago on May 19
Schaumburg, Illinois (USA)-Hunter Automated Machinery today announces an open house, to be held at company headquarters in Schaumburg, Illinois, near Chicago, next Thursday, May 19, from 8 A.M. to 5 P.M. During this event, plant tours will be conducted, plus demonstrations will be offered on a new grinding center from Maus, one of Hunter’s machinery partners, whom Hunter represents in North America.
The SAM 600G is a fully automated CNC automatic grinding center, compact yet powerful, with four-tool capacity and a product load/unload time less than four seconds. 
Built with a rotary turntable for loading/unloading of the workpieces, this Maus machine can significantly improve the finishing operations. Multi-spindle grinding is programmable for cutting of risers and gating, plus surface and internal grinding.
In the North American market, Hunter also represents Space’, Primafond and Versatile, all builders of related foundry equipment for metalcasting.
Hunter and its partners will all be exhibiting at GIFA, the international foundry exposition, upcoming June 28-July 2, 2011 in Dusseldorf, Germany.
For further information on this announcement, interested parties may contact:
HUNTER AUTOMATED MACHINERY CORPORATION
2222 Hammond Drive Schaumburg, IL 60196
Phone: (847) 397-5110
Fax: (847) 397-8254
Email: info@hunterfoundry.com
Web: www.hunterfoundry.com
Connect with Hunter Foundry online: 
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The Maus SAM 600G, a CNC grinding center for cast metals finishing, will be introduced to the North American foundry market at an open house, to be held at Hunter Automated in Schaumburg, IL, near Chicago, on May 19.
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CHICAGO, April 5, 2011 — At this year’s AERODEF show in Anaheim, California, Siemens will demonstrate new solutions and services for machine tool end-users and manufacturers. Under the theme, “Productivity in motion,” the presentation will focus on turnkey solutions for the aerospace manufacturing industry.
For machine tool end-users and OEMs, Siemens will exhibit new value-added services ranging from condition monitoring and manufacturing IT to innovative solutions for CNC training and machine tool retrofit, as well as the newest innovations in CNC (computer numerical control), motor and drive technology.
SOLUTIONS FOR MANUFACTURING EXCELLENCE
Condition Monitoring and Manufacturing IT are two value-added services that are continuing their introduction to the U.S. machine tool market.
Condition Monitoring is an internet-based service from Siemens that supports maintenance processes while simultaneously forming a platform for cross-company service and support between OEMs and machine operators. Services can be configured over secure Internet connections from anywhere in the world via a standard PC, an internet connection and a web browser.
Manufacturing IT solutions from Siemens provide software tools for fast, easy integration of machines in a production network, while ensuring that production planning, scheduling and execution
is always problem-free and based on the very latest data.
An entire line of powerful software modules for production machines ensures optimum integration of the machines in the IT-environment and supports a wide range of different functionalities including:
SOLUTIONS FOR AEROSPACE
For the aerospace market, the new Sinumerik 840D solution line is the latest in CNC technology that increases performance and user productivity. The Sinumerik 840D sl is a universal and flexible CNC system featuring the innovative Sinamics S120 drives that can be used for up to 31 axes. It is a distributed, scalable, open and inter-connecting system offering a wide range of specialized functions for milling, drilling, turning, grinding and handling technologies.
The Sinumerik 840D offers users innovative features that increase productivity on the manufacturing floor, especially the challenging segments of high-speed and five-axis aerospace machining.
SOLUTIONS FOR THE JOB SHOP
For the job shop, the new Sinumerik 828D numerical control will be presented. Perfect for
mid-range machine tools, the Sinumerik 828D is designed to address the needs of complex milling and turning machines in the job shop segment. It combines CNC, PLC, operator panel and axis control for six CNC measurement circuits in a single, robust operator panel.
The Sinumerik 828D is capable of full graphical, high-level language command and supports ISO programming that is customary in the United States. Programming time can be further reduced for small-batch production with the use of the ShopMill and ShopTurn graphical workstep programming system, while high-level language programming can be used in conjunction with programGuide to significantly reduce programming times for large-scale serial production.
With the introduction of the Sinumerik 828D, modern PC and mobile phone technology is now available to the mid-range machine tool. Extensive online help animations and a new type of input prompting system with moving picture sequences provide the basis for exceptional user convenience. USB, Compact Flash (CF) card and Ethernet ports enable high-speed data transfers onto storage media or integration of the control system into corporate networks. Through the use of its Easy Message functionality, the Sinumerik 828D offers production status monitoring by text messaging (SMS). Depending on the recipient’s profile setting, the machine will transmit information about workpiece machining status, report on the tool condition currently in use and send machine maintenance bulletins to a mobile phone, anytime and anywhere. These combined functions are designed to help keep machine downtime to a minimum.
SOLUTIONS FOR CNC TRAINING
Newly introduced to the American machine tool industry, and based upon the new Sinumerik Operate user interface, SinuTrain is the ideal solution for control-identical CNC training.
With SinuTrain, actual NC programs are developed and simulated, to speed the program generation protocol. In this way, machine tool operators not only learn the control language commands, but they also visualize part programs on a PC screen that are identical to the machine tool’s screen. As a further benefit, programs generated through SinuTrain can then be used on actual machines.
SinuTrain is available for different needs and budgets including a trial version, a study version, a single-user license and an educational license. It is available in English, Spanish, French, German, Italian and Simplified Chinese, and requires Windows® XP (32-bit). Support for Windows 7 (32- / 64-bit) coming in 2011.
For more information about CNC solutions and services from Siemens, point your web browser to www.usa.siemens.com/cnc.
For specific product information and inquiries:
SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communication
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit http://www.usa.siemens.com/industry.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.
Continue readingSixteen precision 112.5º gearboxes fully manufactured, tested, assembled and shipped in ten weeks; run at 1800 RPM on 100 HP
Excel Gear, Inc. of Roscoe, Illinois announces the completion of a sixteen gearbox order in only ten weeks. Seems rather normal, until you see the application, namely, one of the world’s largest ever vibratory pile drivers, the APE Octokong, to be used for erection of an over/underwater structure, the Hong Kong-Zhuhai-Macau Bridge in China. The machine is being built by American Piledriving Equipment, Inc. (APE) of Kent, Washington. In use, the sixteen gearboxes regulate timing on the vibratory power transmission for the apparatus needed to secure the pilings in the riverbed or sea floor. For a video of this amazing machine design, see www.apevibro.com.
Using its “design for manufacturability” approach, according to N.K. “Chinn” Chinnusamy, Excel Gear president and its chief engineer, the company manufactured the spiral bevel gears, machined the castings, engineered special Teflon seals, created 
special stainless steel breather caps and holes to accommodate the tremendous pressure build-ups and air dissipation requirements in the system, then heat treated and assembled the units, finally testing them in the Excel quality inspection lab. Each component was hand-washed and inspected for chips, the alcohol-wiped, run with oil, inspected and re-cleaned.
The sixteen gearboxes, filled with environmentally-friendly biodegradable canola (vegetable) oil and protected with special Teflon bearing seals, are used in pairs at each of eight stations to provide the sequential vibration to the massive assembly that holds the piling above the insertion tube. As the piling vibrates, it literally shakes its way into position. (This is shown in the video.)
“The toughest part of this job…and there were many tough parts,” comments Chinn, “was to get the shaft keyways aligned properly in orientation to the surfaces of the spiral bevel gears. The math involved here was staggering.” In addition, Chinn notes that special fixturing had to be built to facilitate the machining of the very large surface areas involved on this job. He proudly reports that the very first test runouts saw keyway alignments within 0.0005” of parallel. 
Another aspect of this immense job was the need to minimize backlash for noise and distortion. The offset bearing calculations needed the highest accuracy possible and, owing to the very nature of spiral bevel gearing, this was an immense math and machining challenge. Excel maintains a battery of the largest gearmaking machines in the industry, as its customer base comprises heavy materials handling equipment, naval vessel gun turret builders, barge off-loading crane and other manufacturers where huge gears and precision motion are both required.
Despite the timing of the job, Excel Gear shipped the order ahead of schedule by several days, satisfying the customer completely. Chinn acknowledges several suppliers who greatly assisted Excel in the completion of this job. Youngberg Industries of Belvidere, Illinois performed some of the heavy fabrications needed, while Reliance Gear of Addison, Illinois did spiral bevel gearwork, a highly specialized service, and General Surface Hardening in Chicago handled the carburizing and hardening in the heat treat processes on the 4320 alloy steels used. Finally, Chuck Schultz of Beyta Gear Surface in Winfield, Illinois did some consulting and spec writing on the job.
For more information on this success, please contact: EXCEL GEAR, INC. 11865 Main Street Roscoe, IL 61073 Phone: 815-623-3414 Fax: 815-623-3314 Web: www.excelgear.com Email: sales@excelgear.com N.K. Chinnusamy, President 
No. 829 is an electrically-heated 250°F(~121.11°C) belt conveyor oven from Grieve, currently used for curing epoxy on metal and nylon filter assemblies. 40 K are installed in Incoloy sheathed tubular heating elements. Workspace dimensions are 30” wide x 10’ deep x 15” high.
The oven has 4” insulated walls and an aluminized steel interior and exterior. A 4200 CFM, 3-HP recirculating blower provides vertical upward and downward airflow to the unit. The oven has three zones: a 2’ long open belt loading zone, 10’ long insulated heat zone with recirculated airflow and a 2’ long open unloading zone. The product is moved through the oven on a 24” wide, 1” x 1” Type 304 stainless steel flatwire conveyor belt with a 1/4 HP motor drive, with variable speed from 0.3 to 6 feet per minute.
Controls onboard No. 829 include a digital indicating temperature controller, manual reset excess temperature controller with separate contactors, SCR power controller, fused disconnect switch and a recirculating blower airflow safety switch.
For more information, please contact: THE GRIEVE CORPORATION, 500 Hart Road, Round Lake, Illinois 60073-2835 USA. Phone: (847) 546-8225. Fax: (847) 546-9210. Web: www.grievecorp.com. Email: sales@grievecorp.com. Attention: Frank Calabrese.
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