Application Worksheets

Direct Drive Application Sheet

E-Trac Direct Drive Application Sheet

E-Trac (metric) Direct Drive Application Sheet

Shaft Drive Application Sheet

Swing Drive Application Sheet

Track Drive Application Sheet

Wheel Drive Application Sheet

Wheel Drive (metric) Application Sheet

Analysis & Application Calculations

• Full FEA capability based on Solid Edge software
• Power Gear gear design program, AGMA based
• Gear life calculations based on duty cycles
• Application analysis
• Bearing life calculations
• Tolerance Stack-ups & clearance / fit analysis
• Failure analysis
• FEA data correlation with lab / field testing

Heat Treatment

AG LLC operates its own captive heat treat department and has in house capabilities of processing nearly all of our material and gearing heat treatment requirements.

In house process capabilities include:

Batch furnace processing for:

Carburizing & Oil quench
Carbonitriding & Oil quench
Neutral hardening & Oil quench
Atmosphere quenching
Selective case hardening
Batch tempering

Induction hardening with continuous furnace tempering

Atmosphere Heat Treat Processing Equipment

One 36 – 48 – 36 integral quench batch furnace with top cool capabilities
One 36 – 48 – 36 integral quench batch furnace
One 20 – 36 – 24 integral quench batch furnace
Two 36 – 48 batch temper furnaces
One 24 – 36 batch temper furnace
Endothermic gas atmosphere generators
Nitrogen furnace purge / atmosphere

Auxiliary Processing Equipment

Shot peening
Abrasive grit blast cleaning
Straightening

Quality Assurance

AG is ISO 9001:2008 registered and maintains a Quality Management System that supports engineering planning & design, manufacturing process control and continual improvement of our products and services.

QA Personnel

Auburn Gear has a fully staffed Quality assurance and Inspection operation

• 3 shift coverage to support manufacturing
• 2 Certified Quality Engineers
• One certified level II NDT inspector in MP
• One certified level III NDT inspector in MP
• All personnel are cross-trained in the myriad of our Inspection Lab processes

Quality inspection Systems

The Quality Assurance department and Gage Lab is an ISO compliant department and utilizes work instructions and procedures to document and insure consistent inspection of our products manufactured on site and purchased.

• First Article verification of all features of new or revised parts.
• Set-up approval for every work order before the parts are manufactured.
• All processes are documented for consistent results.
• Quality Engineering supports Manufacturing as well as the Engineering Department with Engineering Lab checks as well as special checks for Manufacturing Engineering.
• Non-conforming material is quarantined and reviewed daily for disposition
• Processes – Quality department personnel make use of computer-based processes to support Manufacturing and Engineering.
• Mini-Tab Statistical Analysis software.
• Gage Calibration is maintained in the business software system for accountability and consistently performing inspection equipment.
• Capability Studies are performed periodically per customer request and for manufacturing process surveillance.
• Support Engineering as an in-house Geometric Dimensioning and Tolerancing consultant.

Auburn Gear Manufacturing Capabilities

(2) Gleason CNC Vertical Hobbing Machines 1998 & 2012

Cylindrical Gear hobbing with Internal Bore Clamping
Maximum Diametral Pitch 8.50
Maximum outside Diameter 5.118”
Automated loading for unattended operation

(2) CNC Horizontal Hobbing Machines

For shaft work
Retrofitted Barber Colman 14-15 with CNC Controls
Outside Diameter clamping with tail stock center support

(12) Horizontal Barber Colman Hobbing Machines

(2) with Double Cut capabilities
(2) with Long Bed Capacity

(6) Shave Machines

For shaving of spur gears with crowning capabilities

Internal Spline and Gear Broaching

– Horizontal and Vertical machines
– Machine capacity of 50 tons with 90” Stroke, Vertical Table Up

Internal and External Shaper Cutting of Splines and Gears

(9) Fellows Shaper Machines
(4) with CNC controls with slotting and sector cutting capabilities
(2) with Tailstock for shaft work
(1) with 9” raise new in 2014
– 20” Maximum Diameter, with 8” face width, 3.0 Diameteral Pitch

Straight Bevel Gear Cutting and Roll Testing

Gleason Revacycle ® and Coniflex ® Machines

(6) 4-axis lathes, Cincinnati and Mazak

– Capable of simultaneous internal and external machining

Phosphate Coating Line (lubrite)

Assembly and testing of Differentials

Load Monitoring for Torque Bias
PLC Controlled for testing in forward and reverse directions
Engage and disengage coil for ECTED

Mori Seiki NT-4300 Mill-Turn Center (4)

– (3) with Full contouring B-axis – 2013 & 2015
– (1) with B-axis indexing of 1 degree – 2012
– (9) programmable axes
– Both Main and Sub-Spindles 40 HP
– 28.7″ swing
– 100 Tool Magazine
– 20 Tool Lower Turret
– In Machine Measuring Device
Renishaw probe used to locate features on a part or casting with ability to orientate any necessary machining from the originally located feature

(1) Robot with 150 pound part capacity and end of arm tool changer to load and unload two machines
(1) Robot with 250 pound part capacity and end of arm tool changer to load and unload two machines with integrated vision system
Capable of turning, milling, Drilling, tapping parts complete in one setup
Gear and spline generating capabilities up to 2.0 Diameteral Pitch

2-axis Lathes

Steel and Cast Iron Turning
ID Collet Chucks
OD Collet Chucks
Tail Stock Supports
3-Jaw Chucks up to 15”
(4) with Live Tooling

 (6) Motch Vertical CNC Chucker Lathes

Large part, approx. 24” OD and ID Turning
Upgraded with Fanuc 0-i series control in 2011

Vertical Machining Centers

Thru Spindle Coolant
CAT 40 and CAT 50 Spindles
(2) with Full Contouring 4-axis
(1) with 4th axis indexer .001 Degree accuracy
(1) Pallet Changer
(1) High Pressure Coolant for Deep hole drilling

 Hardturn Capabilities on 2-axis and 4-axis Lathes Software

– ESPRIT CAM software used for programming
– Solid Edge CAD software

Mori Seiki NL-2500 Turning Centers (2)

Sub-spindle
Live Tooling
Y-Axis
High Pressure Coolant
In Machine Gear and Spline generating ability

(1) With Bar Feeder

Capacity up to 3.1”
Shafts up to 24” length
Shaft unloader table thru sub-spindle
Both Main and Sub-Spindle OD Collet Chucks
Unattended operation utilizing parts catcher

(1) With Robot

3-jaw chuck with 10” capacity
ID Collet Chuck on Sub-spindle
Robot Load and Unload capable of handling parts up to 40 pounds

Grinding

I.D. Grinding

O.D. Grinding

• Profile Cam
• Plunge
• Center-less
• Blanchard

CNC I.D. Grinding

• Robot Load and Unload
• Integrated Gaging with feedback loop back to CNC to control size

(4) Assembly Lines for planetary wheel drives

PLC Controlled presses to set bearing pre-load while rotating the unit to achieve unmatched precision and consistency.
PLC controlled end of line testers used to drive the wheel thru the input of planetary in both the forward and reverse directions, while using air to check for any potential oil leaks.
For units equipped with integrated parking brake, the break is released during the spin test and held in position to detect any leak down.