Equipment & Capabilities
| GEAR HOBBERS |
| Qty |
Description |
| 2 |
KOEPFER 200 CNC 7-AXIS AUTOMATED LOADING WITH WORM MILLING HIGH HELIX HOB HEAD (2007) |
| |
|
| 1 |
KOEPFER 153B HOBBBER W/ AUTOMATED LOADING & CROWNING (1993) |
| |
|
| 1 |
KOEPFER 300 CNC 7-AXIS AUTOMATED LOADING WITH SKIVING (2004) |
| |
|
| 4 |
KOEPFER 200 CNC 7-AXIS AUTOMATED LOADING WITH SKIVING (1997,1999, 2001, 2003) |
| |
|
| 1 |
KOEPFER 153B WITH CNC AUTO LOAD (1994) |
| |
|
| 1 |
KOEPFER 180 CNC AUTO LOADING (1996) |
| |
|
| 2 |
GLEASON 125 GH CNC – AUTO LOADING & CARBIDE REHOBBING, SPECIAL ACCURACY (1997, 2001) |
| |
|
| 2 |
GLEASON 400 CNC (1998, 1998) |
| |
|
| 4 |
KOEPFER 160B, (2) EXTENDED (1998, 2002) AND (2) STANDARD (1998, 2004) |
| |
|
| 1 |
KOEPFER MZ130 (2008) CNC AUTOLOAD GEAR AND WORM HOBBER |
| |
|
| 1 |
PFAUTER PE 125 HORIZONTAL 6 AXIS - 800MM SPLINE LENGTH (1995 ) |
| |
|
| GEAR SHAPERS |
| Qty |
Description |
| 1 |
FELLOWS/BOURN & KOCH MS450-125 CNC SHAPER WITH CROWNING (2008) |
| |
|
| 1 |
LORENZ 420 CNC MOVING HEAD SPECIAL ACCURACY SHAPER |
| |
|
| 1 |
MITSUBISHI ST25 CNC HIGH SPEED GEAR SHAPER (2006) |
| |
|
| 1 |
MITSUBISHI ST40 HELICAL QUICK RETURN GUIDELESS 5 AXIS CNC SHAPER (2004) |
| |
|
| 1 |
GLEASON PSA 300 WITH ELECTRONIC HELICAL GUIDE FEATURE & AUTOMATIC COLUMN INCLINATION , SPECIAL ACCURACY (2008) |
| |
|
| 2 |
GLEASON PSA 500 WITH ELECTRONIC HELICAL GUIDE FEATURE & AUTOMATIC COLUMN INCLINATION WITH FACE GEAR ATTACHMENT. 200 MM STROKE SPECIAL ACCURACY (2003, 2008) |
| |
|
| GEAR AND THREAD GRINDERS |
| Qty |
Description |
| 1 |
HOFLER HELIX 400 SK (2008) |
| |
|
| 1 |
DRAKE GS:TE-LM CNC THREAD GRINDER (2006) |
| |
|
| 1 |
KAAP VUS55P FORM GEAR GRINDER WITH INTERNAL GEAR GRINDING (2005) |
| |
|
| 1 |
SAMPUTENSILI RI 400 TWIN GEAR GRINDER (2002 |
| |
|
| 1 |
SAMPUTENSILI RI 375 CNC GEAR & THREAD GRINDER WITH INTERNAL GEAR GRINDING (2008) |
| |
|
| QUALITY ASSURANCE EQUIPMENT |
| Qty |
Description |
| 1 |
KLINGELNBERG P65 ANALYTICAL CNC CHECKER (2002) |
| |
|
| 1 |
WENZEL GEAR TEC LH87 CMM WITH ROTARY TABLE (2008) |
| |
|
| 1 |
WENZEL GEAR TEC WGT 600 ANALYTICAL CNC CHECKER (2007) |
| |
|
| 1 |
PRECISION GAGE G3 GEARMASTER 15" C.D. WITH HIGH CENTER & WORM ATTACHMENT (2006) |
| |
|
| 1 |
PQ SYSTEMS GAGEPACK CALIBRATION SOFTWARE (1999) |
| |
|
| 1 |
GLEASON 6 UNIVERSAL ANGULAR POWER GEAR TESTER |
| |
|
| 1 |
UNIVERSAL TECHNICAL SYSTEMS GEAR ANALYSIS SOFTWARE AND TK SOLVER WITH 2008 VERSION |
| |
|
| 1 |
ZEISS STEMI 2000C MAGNIFICATION SYSTEM |
| |
|
| 1 |
DIGIT DOB.8 -MEASUREMENTS OVER AND BETWEEN PINS (2006) |
| |
|
| 2 |
MITUTOYO DIGIMATIC HEIGTH GAGE MODEL HDS H24C (2007) |
| |
|
| 4 |
MAHR HEIGTH GAGES (2006-2007) |
| |
|
| 1 |
WENZEL GEAR TEC 350 ANALYTICAL CNC CHECKER (2005) |
| |
|
| 1 |
MITUTOYO SURFACE TESTER SV-3000 WITH SURFPAK SOFTWARE (2004) |
| |
|
| 1 |
ZEISS CONTURA COORDINATE MEASURING MACHINE (2001) |
| |
|
| 2 |
MAHR DOUBLE FLANK ROLL TESTERS (2001) |
| |
|
| 1 |
HOMMELWERKE Z2000 CNC GEAR COMPUTER, DOUBLE FLANK ROLL TESTER (1988) |
| |
|
| 2 |
9N PARKSON ROLL TEST UNIT WITH WORM ATTACHMENT |
| |
|
| 19 |
VARI-ROLL GEAR CHECKERS & MASTER GEARS, (1) VARI-ROLL 4000 VARI PC |
| |
|
| 1 |
OPG OPTICAL COMPARATOR QL20STD WITH SMART CHECK SOFTWARE (2001) |
| |
|
| 1 |
ILLINOIS TOOL WORKS #265 HOB CHECKER |
| |
|
| 2 |
FEDERAL AIR BORE GAGE (2000, 2006) |
| |
|
| 5 |
SUNNEN BORE GAGE |
| |
|
| 1 |
WILSON /INSTRON HARDNESS TESTER TT SERIES 2000 (2003) |
| |
|
| 1 |
AST ROLL SCAN 200-1 GRIND BURN DETECTION CHECKER (BARKHAUSEN EFFECT- 2004) |
| |
|
| 1 |
VINCO OPTICAL DIVIDING HEAD |
| |
|
| 1 |
CIMWORKS VISUAL SPC SHOPFLOOR SOFTWARE (2000) |
| |
|
| 1 |
PQ SYSTEMS GAGEPACK CALIBRATION SOFTWARE (1999) |
| |
|
| 1 |
UNIVERSAL TECHNICAL SYSTEMS INTEGRATED GEAR ANALYSIS SOFTWARE AND TK SOLVER VERSION 6.0.3 |
| |
|
| 1 |
COMPLETE INSPECTION ROOM--CERTIFIED MASTER TO MIL-L-45208A, GAGE CONTROL MIL-STD-45662, ISO 9001:2000; AS 9100; ISO 13485 MEDICAL CERTIFICATE |
| |
|
| SECONDARY EQUIPMENT |
| Qty |
Description |
| 1 |
SUNNEN SV1005 CROSS GRIND HONE (2007) |
| |
|
| 2 |
KELLENBERGER KEL-VISTA TYPE UR UNIVERSAL CYLINDRICAL GRINDING MACHINE MODEL 175-600 (2007) |
| |
|
| 1 |
CLAUSING COLCHESTER MASTIFF V/S LATHE (2003) |
| |
|
| 1 |
TAKISAWA TC-10 AUTOLOAD SECONDARY LATHE (2000) |
| |
|
| 1 |
VALE ESMA CHEMICALS ULTRA SONIC CLEANER (1989) |
| |
|
| 2 |
HURCO VM-1 MACHINING CENTER (2007) |
| |
|
| 1 |
WILTON VSG 20 DRILL PRESS (2000) |
| |
|
| 1 |
DENISON 4 TON HYDRAULIC MULTI-PRESSES |
| |
|
| 5 |
HARDINGE LATHES |
| |
|
| 1 |
HIGH SPEED SPECIAL ACCURACY CENTERING MACHINE |
| |
|
| 1 |
CHEVALIER 3 AXIS SURFACE GRINDER (1998) |
| |
|
| 1 |
5 TON, 48" STROKE HORIZONTAL OHIO BROACH (REBUILT 1998) |
| |
|
| 1 |
SUNNEN MHS-401 CROSS GRINDING HONE W/AUTO LOAD (1999) |
| |
|
| 1 |
SUNNEN EC-3500 POWER STROKED HONE W/ AUTO LOAD (1999) |
| |
|
| 1 |
SUNNEN EC-3500 POWER STROKED HONE (1994) |
| |
|
| 1 |
JENFAB MINIBELT WASHER/DRYER (2007) |
| |
|
| 1 |
TASC MASTER AQUEOUS CLEANING SYSTEMS |
| |
|
| 2 |
CHAMFERMATIC DEBURRING MACHINES (2000, 2001) |
| |
|
| 1 |
ROTO-FINISH GEMINI VIBRATORY TUMBLER (2001) |
| |
|
| 1 |
COMCO PRO CENTER DF1400 MICRO BLASTER WITH 20X OPTICS MICROSCOPE |
| |
|
| 1 |
ROFIN A-B LASER STARMARK ENGRAVER (2001) |
| |
|
| 1 |
HURCO CNCVMX42 MILLING MACHINE (2005) |
| |
|
| ADDITIONAL EQUIPMENT |
| Qty |
Description |
| 1 |
STAR/SU PTG-1 HOB AND SHAPER CUTTER SHARPENER (2008) |
| |
|
| 1 |
SAIKUNI CNC HOB SHARPENER (2001) |
| |
|
| 1 |
HEALD SHAPER CUTTER SHARPENER (REBUILT 2001) |
| |
|
| 1 |
BARBER-COLMAN MODEL HOB SHARPENER (2 1/2-2) |
| |
|
| 1 |
DOALL MODEL 10 UNIVERSAL TOOL & CUTTER GRINDER TC-10 (1988) |
| |
|
| 1 |
KOEPFER HOB SHARPENER WITH SPIRAL GASH(2002) |
| |
|
Other Capabilities
Crown Hobbing
Forest City Gear has pioneered fine pitch crown
hobbing, a unique technology we apply to fine pitch gearing. This
process produces a barrel shape on the flank of the gear tooth
that compensates for misalignment and reduces noise. This application
is especially advantageous with high-speed spur and helical pinions
Carbide Re-hobbing (commonly referred to as skiving)
Forest City Gear’s carbide re-hobbing process
allows us to produce the highest quality gears at a lower cost
than grinding. Carbide re-hobbing eliminates distortion caused
by heat treating, allowing us to achieve gear quality of AGMA 9
or better. Gears that have been distorted or enlarged during heat
treatment can be salvaged with this process.
Analytical Gear Inspection
Forest City Gear’s state-of-the-art analytical
inspection equipment shows our commitment to quality. This equipment
is capable of checking pitch, runout, lead, and profile error to
ten millionths of an inch on spur, helical, worm and worm gears
as well as on hobs and shaper cutters. We have performed analytical
inspection on gears as fine as 96 diametrical pitch and with diameters
up to 35 inches.
Hob Sharpening
Forest City Gear realizes accuracy of a gear’s
profile is determined by the quality of the hob being used to generate
the teeth. Our modern hob-sharpening equipment allows us to re-sharpen
hobs consistently to class AA tolerances.
Gear and Thread Grinding
Forest City Gear's form grinder offers "Master
Gear Quality" for single and multi-thread worms. This machine is
capable of handling heavily modified profiles and crowned teeth
to 370mm diameter and shafts to a meter in length. For spur and
helical gears, we have ground master gears as fine as 80DP from
solid or finished roughed gears achieving qualities as high as
AGMA 14 or 15 (DiN 2-3) on some parameters, and even better occasionally.
Types of Gears
| Gear Type |
Max O.D. |
Diamentral Pitch |
|
| Thread Grinding |
20" |
Worm to 4 DP & 1 Meter Length |
| Gear Grinding |
20" |
3 DP-52 DP |
| Spur Hobbing |
20" |
3 DP-200 DP |
| Spur Shaping |
24" |
3 DP-200 DP |
| Helical Hobbing |
20" |
3 DP-200 DP |
| Helical Shaping |
24" |
3 DP-200 DP |
| Worm Gear |
16" |
4 DP-200 DP |
| Worm |
5" |
6 DP-200 DP |
| Sprocket1 |
20" |
3/4" CP (Coarsest) |
| Spline2 |
20" |
4 DP-200 DP (to 31.5" Length) |
| Internal |
20" |
4 DP-200 DP (to 5" Facewidth) |
1 Includes roller, block,
silent, and ladder chain type sprockets.
2 Includes tapered, involute, straight-sided and serration
type spline shafts, and jump spline shafts.
NOTE: We do not manufacture bevel gears, miters, herring bone, shaved,
gear reducers or gear boxes.
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