Document mBRZg9L9bDy81Jr56BD19y2zg

Page 17 G. L. Cotter May 3, 1985 end program would result if we developed pre- and post- processing programs that could convert machine settings we know or need into or from the type settings with which "SPBEVL" is known to successfully work. Effects of Near Net Gear Forging and CBN Grinding - Conventional (standard production forgings) pinion forgings have been received from Marion. These ate all of the same heat lot and in a quantity large enough to cover the entire test program as it currently stands. Gleason Works has responded with a verbal cost estimate for development, Zeiss inspection, and single flank Inspection required to process the test lots associated only with the 16.5 P.D. 4.33 ratio. A written quote is expected to follow shortly. Soft Test Procedure and Practice - Recently Production experienced problems while attempting to lap Model 23220, 6.17 ratio (53172 and 53171) gear sat in terms of tooth contact interference between the top of the gear tooth and the flank of the pinion tooth. This is not an acceptable condition due to the high noise level generated by running interference as well as the eventual tooth surface related failures (pitting or spalling), which would occur were these gear sets to be placed in service. Gear Engineering personnel have evaluated both single and two-speed soft masters as well as a hard finished sample. All parts checked are out of specification in terms of gear whole depth and chordal thickness, and pinion chordal thickness. Based upon these findings, it is recommended that single and two-speed gear sets produced since March 11, 1985 be scrapped versus being sent to the warehouse for reprocessing and distribution at a later date. To avoid a repeat of this situation, it is recommended that chordal thickness be measured and verified on all existing masters, and again measured when replacement production masters are made. This responsibility must fall within the soft test procedure, and be a required practice of those individuals responsible for generating replacement production masters. DESIGN SERVICES Data Conversion - Currently two third party software houses have been reviewed to write a translator that would allow us to transfer Appllcon files to CADAM so we can communicate graphics to our customers that use CADAM. The cost of this translator is approximately $20,000. Octal, Inc. has received files from us on an axle installation drawing to perform a benchmark of their translator. A BRAVO! user manual ('BUM') has been outlined to help establish correct techniques to be used in Galesburg and possibly at our plant locations. Individuals performing tasks outlined in the manual are asked to contribute techniques and use techniques previously established. CAD meetings are tentatively scheduled about every ten days.