P09702: Gleason Gear Quenching Machine
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Project Overview

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Gleason is a global leader in gear production technology. Our gear production technology is used extensively in many major industries: Aerospace, Automotive, Energy, Maritime, Rail, and Trucking. The Gleason Works has significant resources to develop and produce a broad portfolio of machines, tooling, and technology. However, with such a broad base of products comes the responsibility and challenge to offer our customers the highest value solution to their requirements. Due to resource constraints, we have not had an opportunity to dramatically improve our Quenching process equipment. However, we believe a focused design effort from a multi-disciplined engineering team could renew this product line, and offer Gleason Rochester Work an opportunity to improve the functionality, manufacturability, and ultimately the profitability of this machine.

A Quenching machine is a critical piece of equipment used by almost all gear manufacturers. Quenching is a critical heat treating step that yields an optimum combination of strength and ductility for gears. The machine operates by taking a gear that has been heated above 1400F and moving it to the quenching position. The gear is constrained by using a hydraulic ram and die arrangement to prevent distortion during cooling. An oil bath is circulated around the periphery of the gear in order to insure uniform cooling of the part. Uniform cooling using a mineral oil bath insures proper hardening characteristics within in the cross-sectional area of the part as well as in subsequent processed parts. Once the part has been properly quenched, the gear is tempered to stress relief forces induced by quenching. Tempering increases ductility or resistance to fracturing. This process is critical to the longevity of geared products.

Administrative Information

Project Name
Gleason Gear Quenching Machine
Project Number
P09702
Project Family
Manufacturing Process and Fabrication
Track
Manufacturing Process and Fabrication
Start Term
2008-1
End Term
2008-2
Faculty Guide
John Kaemmerlen
Faculty Consultant
consultant name here (consultant dept here)
Graduate Teaching Assistant
ta name here
Primary Customer
Alan Metelsky, Manager, Controls Engineering
Customer contact information
Gleason
Contact info for Alan - ametelsky@gleason.com, 585 784-6927
Team Structure

Team Structure

Mechanics Team

Log

Controls Team

Controls Log

Team Documents

Frame_iso_new.bmp
Frame_iso_old.bmp
Frame_sec_new.bmp
Frame_sec_old.bmp
MSD II Schedule.xls
Project Summary
Updated Needs Assessment.doc
Feasibility and Risk Assessment.xls
Team Values.doc
Team Schedules.xls
Gleason's Ideas.doc
Access Panels Modifications.xls
Action Items 12-8.xls
quarter plan
plan week 4
PLC final review
MSDII weekly plan - Electrical Wiring
Electrical Suppression Power Bus Slides

For a copy of other project materials, email jxkpdm@rit.edu.

Planning

Mission Statement

Customer needs: The Gleason Rochester Works has a need to apply engineering talent to modernize a machine line and to reduce fabrication and manufacturing costs. We require a multi-disciplined team to evaluate the current design, and with technical guidance provide innovative, cost effective solutions to a challenging set of technical problems. Design for manufacturability, design of control and safety systems, PLC programming, and mechanical system design skills will be required for this project.

Customer deliverables:

Several opportunities have already been identified. We believe this project has an opportunity to go beyond a two quarter senior project; it has the opportunity to be applied across multiple senior projects given the possible scope of this project. Progress Report: Expect to meet once a week via teleconference to discuss progress, action items, issues, and concerns. Once a month we expect to have an on site meeting with Senior project team. In addition as designs are completed we expect to have a formal design review: DFM, FMEA, and Risk Analysis.

Customer and Sponsor Involvement:

Gleason Engineering will provide an Engineering Manager level mentor to provide direction, guidance, and feedback to the project team. In addition, mechanical, electrical, and industrial engineering support and guidance will be provided. We expect to bolster team with Gleason Engineering staff.

Regulatory requirements (i.e. UL, IEEE, FDA, FCC, RIT):

All relevant safety and country/regional area regulatory requirements will be adhered to. This will be the responsibility of the Gleason Engineering Staff.

Project Budget and Special Procurement Processes:

Gleason will provide development support, and will fund all relevant expenditures to this project. Other: This project will provide a Senior Design Engineering Team an excellent opportunity to experience a project that requires multi-disciplined solution; also, it will provide real solutions that will be applied to a product. This is a low volume product; therefore it is not a critical path project.

Staffing Requirements Use WBS and associated resource estimates to summarize anticipated staffing needs: EE (Electrical controls, PLC programming, pneumatic, and hydraulic design); ME (Mechanical layout and design, strength of materials knowledge); CE; ISE (Design for manufacturability, ergonomics, and safety, PLC programming)

Intellectual Property Considerations None

Preliminary Work Breakdown Structure

Team Values and Norms

Grading and Assessment Scheme

We have brainstormed a list of enhancements we could offer for this product, and we will provide direction for the project team on the feasibility, cost/benefit, and risks involved. We expect Gleason Engineering and the Senior Design Team to prioritize the list and prune the list to a reasonable number of enhancements.

Required Resources

Concept Development

Identify Customer Needs

Establish Target Specifications

Generate Product Concepts

Select Product Concept(s)

Test Product Concept(s)

Set Final Specifications

System Level Design

Product Architecture

Detail Design

Design for Manufacturing and Assembly

Robust Design

Design for the Environment and Sustainability

Design for Reliability

Design for Safety

Testing and Refinement

Prototyping

Published Documents

As you conclude the project, include links to all of your finished and fully polished documents here. The previous sections of the web site contain the entire design history of your project. This section contains the finished products. Add more links as needed.

Concept Design Review Documents (SD I)

Detailed Design Review Documents (SD I)

Managerial Design Review Presentation (SD I)

Technical Conference Publication (SD II)

Poster Publication (SD II)

Managerial Design Review Presentation (SD II)

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Simply Adding Documents

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