Open Gearing: Capabilities

Over 1-million square feet of manufacturing facilities under roof at the geared products plant in Milwaukee.

Steel Foundry Facilities

Melting Facilities

Two basic practice electric arc furnaces:

• 70 ton capacity
• 5 ton capacity

Materials Poured

• Carbon and Alloy Cast Steels
• HY-80 (Mil -S -23008 D)

Casting Size

• 200 - 100,000# unit weight

Heat Treating Facilities

• 16 programmable car-with maximum size of 30' x 24' x 12'
• Water quenching equipment available with maximum size of 24' x 24' x 11' with 10-25 hp agitators

Nondestructive Testing Facilities

• Fully Equipped Materials Lab
• 20,000 Amp DuoVac Magnaflux Machine
• Dye Penetrant Inspection
• Ultrasonic Inspection
• Radiographic Facilities Available
• Pattern Shop Facilities

Machine Shop Facilities

Boring Mills

	Vertical:	1-50' Schiess-Froriep*
		1-24' Schiess*
		1-10' Cincinnati*
	* Serviced by 100 ton crane

Vertical Turret

• 1-84" Bullard
• 1-60" Bullard
• 2-54" G&L:
  Also numerous Bullard machines from 36" and up

Boring Bars (Horizontal Mills)

• 2-6" DeVlieg
• 1-8" Ingersoll (serviced by 50 ton crane)
• 1-8" Ingersoll
• 1-5" G & L
• 1-12-1/2" Schiess (serviced by a 100 ton crane)
• 1-7" Gray

Milling Machines

Planer Type:

• 1-12' Ingersoll*
• 2 -7' Ingersol*
• 1-3' Ingersoll*

*Serviced by a 50 ton crane

Lathes-engine

• 1-TCG - 200/8M Poreba Heavy Duty Lathe
• Also, numerous lathes from 13-1/2" diameter

Grinders

• Cylindrical
• Internal Grinder
• Broaching Machines (Horizontal)
• Drilling Machines

Weld Shop Facilities

Gas Cutting

• 2-ESAB CNC controlled Grizzly oxy fuel flame cutter

Laser Cutting

• 1-Cincinnati CL-7 Laser cutter

Presses

• 2-Press Brakes Maximum
• 1-Hydraulic Straightening Press 400 tons
• 1-Hydraulic Forming and Blanking Press 600 tons
• 1-Hydraulic Forming Press 100 tons
• 1-Hydraulic Forming Press 125 tons

Welding Machines

• 1-Automatic Submerged Arc Welding Machine
• 4-Semi-automatic Submerged Arc Welding Machines
• 60-Manual Welding Machines: AC & DC
• 1-Automatic Gas Shielded Welding Machine (circular)
• 20-Semi-automatic Gas Shielded Welding Machines
• 1-ASEA Robot Welder (production runs)
• 1-Stirp Welder (Strip Cladding) 2" Wide Bead

Welding Positioners

• 16-Welding Positioners Range from 500 pounds to 7 tons
• 2-Pairs of Turning Rollers 1-pair (20 ton cap) & 1-pair (60 ton cap)
• 1-Welding Head Manipulator

Annealer

• 1-Car size (16'6" x 27'0") maximum track weight 100 tons (mixed load); 40 tons (one unit load)

Heat Treat Capacities - Carburizing Capacity

Computer Controled

• 1-1.8m diameter x 5.5m deep pit furnace
• 1-1.8m diameter x 2.8m deep pit furnace (with quench tank)
• 1-1.8m diameter x 5.5m deep pit tempering furnace
• 2-Super All-Case Furnaces Internal dimensions: 30"W x 30"H x 48"D
• 1-Super 36 Furnace Internal dimensions: 38-5/8"W x 36"H x 72"D
• 1-Gleason Press Quench To 36" diameter
• 2-Eitel Straightening Press 1-40 ton & 1-277 ton
• 12-Open fire batch furnaces

Large Annealing Furnaces

• 15 total-largest 24' x 30'

Gear Inspection Capabilities

• Maag ES430/55; Transportable involute inspection instrument
• Maag TMC, TMA; Base Pitch Measuring Instrument and tooth to tooth spacing variation
• Klingelnberg PFSU2500; Stationary combination lead/involute inspection instrument, mating gears may be contact checked on centers with pinions which are lead checked
• Maag PH100; Stationary combination lead/involute inspection
• Fette PKM630; 5 axis CNC coordinate lead/involute checking instrument; Software for hob inspection, worm inspection; Bevel and helical gear inspection, rack shaper, cutter inspection; ITW 24"
• Hofler EVTM-HP; Transportable automatic pitch inspection instrument with Hewlett-Packard computer analysis and plotting
• Klinelnberg PNC-130; Stationary CNC combination lead/involute/spacing inspection

Gear Cutting Grinding Facilities

Gear Shaping

• 1-Maag SH1400L; 46' diameter, 50" stroke, .56 DP
• 1-Maag SH600/1200; 35' diameter, 36" stroke, 5/8 DP

Gear Cutters

• 1-30' Hobber (Falk)
• 1-18' Hobber (Falk)
• 1-5 Meter (Schiess)
• 1-3001/4000 Pfauter
• 1-Schiess Pinion Hobber
• Various Other Gear Hobbers, Shapers and Lappers

Gear Grinding Facilities

• 1-4000 Hofler Maxima CNC (with a TPF-40 checker)
• 1-2500 Hofler
• 1-1500 Niles
• 1-1253 CNC Hofler
• 1-Pfauter PE1200 G(Form Grider)
• 1-1500 CNC Hofler Supra