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High demands for cost-effectiveness and improved product quality can be achieved via a new low pressure carburizing process with high pressure gas quenching. Up to 50% of the heat treatment time can be saved. Furthermore, the distortion of the gear parts could be reduced because of gas quenching, and grinding costs could be saved. This article gives an overview of the principles of the process technology and the required furnace technology. Also, some examples of practical applications are presented.
Gear gashing is a gear machining process, very much like gear milling, utilizing the principle of cutting one or more tooth (or tooth space) at a time. The term "GASHING" today applies to the roughing, or roughing and finishing, of coarse diametral pitch gears and sprockets. Manufacturing these large coarse gears by conventional methods of rough and finish hobbing can lead to very long machining cycles and uneconomical machine utilization.
The selection of the proper steel for a given gear application is dependent on many factors. This paper discusses the many aspects related to material, design, manufacture, and application variables. The results of several studies on the optimization of alloy design for gas- and plasma- carburization processing and reviewed.
This paper presents how low pressure carburizing and high pressure gas quenching processes are successfully applied on internal ring gears for a six-speed automatic transmission. The specific challenge in the heat treat process was to reduce distortion in such a way that subsequent machining operations are entirely eliminated.
“Highway vehicles release about 1.7 billion tons of greenhouse gases (GHGs) into the atmosphere each year — mostly in the form of carbon dioxide (CO2) — contributing to global climate change. The CO2 emissions of a car are directly proportional to the quantity of fuel consumed by an engine. In 2013, U.S. greenhouse gas emissions from transportation were second only to the electricity sector — an increase of about 16% since 1990.” (EPA.GOV).
Effective case depth is an important factor and goal in gas carburizing, involving complicated procedures in the furnace and requiring precise control of many thermal parameters. Based upon diffusion theory and years of carburizing experience, this paper calculates the effective case depth governed by carburizing temperature, time, carbon content of steel, and carbon potential of atmosphere. In light of this analysis, carburizing factors at various temperatures and carbon potentials for steels with different carbon content were calculated to determine the necessary carburizing cycle time. This methodology provides simple (without computer simulation) and practical guidance of optimized gas carburizing and has been applied to plant production. It shows that measured, effective case depth of gear parts covering most of the industrial application range (0.020 inch to over 0.250 inch) was in good agreement with the calculation.
When a customer needed gears delivered in three weeks, here’s how Brevini Wind got it done.
In a very general sense, increasing the hardness of a steel gear increases the strength of the gear. However, for each process there is a limit to its effectiveness. This article contains background information on each of the processes covered. In each section what is desired and what is achievable is discussed. Typical processes are presented along with comments on variables which affect the result. By reviewing the capabilities and processes, it is possible to determine the limits to each process.
Indexable carbide insert cutting tools for gears are nothing new. But big gears have recently become a very big business. The result is that there's been a renewed interest in carbide insert cutting tools.
Uncertainty casts a shadow over future business opportunities for manufacturers serving the new energy markets.
This paper introduces new process developments in low-pressure carburizing and carbonitriding using either high-pressure gas quenching or interrupted gas quenching.
In spite of being the "Second City," Chicago has always cultivated a reputation for bigness. We're known for big talk, big shoulders, big basketball players - and big gears. While not necessarily the biggest in the world (more about that late), some Chicago gears are among the hardest working.
This article offers an overview of the practical design of a naval gear for combined diesel or gas turbine propulsion (CODOG type). The vibration performance of the gear is tested in a back-to-back test. The gear presented is a low noise design for the Royal Dutch Navy's LCF Frigate. The design aspects for low noise operation were incorporated into the overall gear system design. Therefore, special attention was paid to all the parameters that could influence the noise and vibration performance of the gearbox. These design aspects, such as tooth corrections, tooth loading, gear layout, balance, lubrication and resilient mounting, will be discussed.
By increasing the number of gears and the transmission-ratio spread, the engine will run with better fuel efficiency and without loss of driving dynamics. Transmission efficiency itself can be improved by: using fuelefficient transmission oil; optimizing the lubrication systems and pumps; improving shifting strategies and optimizing gearings; and optimizing bearings and seals/gaskets.
The October 2011 issue of Gear Technology featured the article “Low-Distortion Heat Treatment of Transmission Components,” which covered the combination of low-pressure carburizing and high pressure gas quenching in an automotive environment. Here, heat treating expert Dan Herring explains why oil quenching is an appropriate choice for many applications.
An offshore jack-up drilling rig is a barge upon which a drilling platform is placed. The barge has legs that can be lowered to the sea floor to support the rig. Then the barge can be “jacked up” out of the water, providing a stable work platform from which to drill for oil and gas. Jack-up drilling rigs were first introduced in the late 1950s. Rack-and- pinion-type jack-up units were introduced soon after that and have dominated the industry ever since.
The main theme of this article is high-capacity, high-speed load gears in a power transmission range between 35 MW and 100 MW for generators and turbo-compressors driven by gas or steam turbines.
Often, the required hardness qualities of parts manufactured from steel can only be obtained through suitable heat treatment. In transmission manufacturing, the case hardening process is commonly used to produce parts with a hard and wear-resistant surface and an adequate toughness in the core. A tremendous potential for rationalization, which is only partially used, becomes available if the treatment time of the case hardening process is reduced. Low pressure carburizing (LPC) offers a reduction of treatment time in comparison to conventional gas carburizing because of the high carbon mass flow inherent to the process (Ref. 1).
News Items About gas
1 Gleason Debuts Opti-Cut Tools for Gashing, Shaping and Hobbing (November 9, 2007)
A new family of cutting tools was recently introduced by the Gleason Corporation for the gashing, shaping and hobbing of gears. This new ... Read News
2 Ikona Launches Six New Gearing Products for Oil and Gas Exploration (April 19, 2006)
Ikona Industries launched six new gearing products for the oil and gas industry at The Global Petroleum Show in June. ?Our oil and ga... Read News
3 Seco to Offer Oil and Gas Solutions at Houstex (December 11, 2012)
At Houstex 2013 in booth 1323, Seco Tools will showcase its oil and gas machining applications expertise, as well as its advanced tooling... Read News
4 Grieve Corp. Releases Gas-Heated Box Furnace (September 23, 2010)
No. 871 is an electrically-heated 2000 degrees F gas-heated box furnace from Grieve, currently used for heat treating and high temperatur... Read News
5 Mazak to Showcase Oil and Gas Production Innovations (December 11, 2013)
Mazak invites oil and gas and other large part manufacturers to its Discover More With Mazak event that’s taking place Jan. 15 and ... Read News
6 Saint-Gobain Gaskets Seal in Temperature Extremes (January 19, 2005)
The OmniGasket from Saint-Gobain is constructed with a layer of PTFE adhered to an alloy base.According to the company's press releas... Read News
7 Ikona Gear Launches Oil and Gas Division, Signs Licensing Agreements (March 9, 2006)
Ikona Gear launched Ikona Industries Corp. to focus on developing, manufacturing and shipping novel gearing applications for the oil and ... Read News
8 GE Oil and Gas to Acquire Allen Gears (December 12, 2013)
Expanding its presence in the industrial gears sector, GE Oil & Gas, recently announced it has signed an agreement to acquire Allen G... Read News
9 Seco to Spotlight Latest Tools for Oil and Gas Applications at HOUSTEX (December 15, 2014)
At HOUSTEX 2015 in booth 441, Seco Tools, LLC will highlight its latest threading, milling and turning cutting tools made to handle the m... Read News