The Fundamentals

of Gear Press
Quenching
L E.."Skilp" J'ooes
Lindberg Technical Be Management Servi,ees, IGIfOUp
Charlotte. NC

Ab tract: Most steel gear applications require

and the re

appreciable loads to be applied that will result

translate into dimensional

in high bending and compressive stre

lion. When we refer to the basic definitions of

the materia] (steen 10 meetthese

criteria.

the gear

must

e. For

performance

be heat

treated.

Associated with this thermal processing is distortion, To control the distortion and achieve
repeatable

dimensional

tolerances,

the gear

will be can trained during the quenching cycle

Ires e within the gears that

I:IIt3nt

changes or distor-

"press" and "quench," we see that

Quench "is th imnree ion of metal into a
liquid to extract h at"; and that
Press "i to exert a teady force or pressure
on a component to achieve a desired shape."
Therefore,

gear press quenching

can be

of the heat treatment process. This type of fix-

defined as "heating

ture quenching is the function of gear quench

condition and then immersing the gear into a

pressing equipment.

liquid to achieve metallurgical transformation,

while at .the sam. time constraining the gear to

Introduction
To understand

press quenching,

a gear to the austenitic

we must

first under tand the phenomenon of quenching

hold size and shape."

The most important
about gear pre,

thing to remember

quenching is that its purpose

is only to can trnin she part and to u e only

enough force to counteract the parts' transfer-

Volume

marion

stres

e . Press

quenehing

designed to reshape or forge gear

is not
into their

finall shape.

Causes of Distortions
Gear distortions

can be caused by several

factors and in any number of combinations. ]n

the heat treating process, the gear is subjected
to both thermal

expansion

and contraction.

Non-unifcrmity

in heating

and cooling

can

cause stresses in a part. which, if large enough.

can cause deformation.

Consideration

must

also be given to the phase changes involved in

hardening

Transfurrnatinn
to ma.rtensite

contractions,

teel that re ult in expan ion

Variations

and

of this stress within

the gear will cause deformation, Material comFig. 1 - Valume changes due to

32

GEAR

TECHNOlOGV

structural transfermatinn,

position variations resulting from the steel pro-

duction process, grain flow variations caused

in forging, and stres es due to pre-heat. treat
machining can all affect the dimensional stabil-

ity of a part during hardening operations.

The magnitude

of the distortion

in heat

treating is affected by the cooling rate, method

of cooling,

transformation

part geometry.

temperature

and

distortion,

it is

To minimize

760c (1400 FI
650 c mODO FI
0

best to use a slow cooling tate and a method

that will maintain

a uniform

540 c (10000 FI
0

temperature

4250 (BODO FI

throughout tile part.

315c (600" FI

It is critical !hat the transformation temperature be consistent throughout the piece, so that
during cooling the entire piece transforms

at

one time. However, a carburizedand hardened

gear that ha

a composition

hence, a transformation

gradient

temperature

and,

gradient,

is more susceptible to distortion. (See Fig. l),

Finally, the shape of a. part strongly influences the degree of distortion it may undergo.
Parts that are large and thin are more susceptible to distortion

than parts that are compact

---

-----------------------

The control of the vapor blanket stage is

critical to the control of a consistent cooling
rate for uniform heat extraction from the gear.

a more viable candidate

Therefore, proper agitation Of rapid movement

of the quench ant is essential to prevent forma-

than is a simple one.

Revie'

or Quenching

Fundamentally.

and Systems

tion of vapor bubbles around the gear which

quench systems, regardles .

insulate it and would result in irregular surface

of the quench media - oil, water, polymer or

hardness and excessive distortion. As a rule of

brine - are similar. Agitation, temperature con-

thumb, proper quenchant movement is defined

trol and quench ant contamination

as a volume flow of oil equal to two to three

of primary

importance.

control are

Since the primary

quench medium used in gear press quenching

is oil, the emphasis win be focu ed here.
The quenching

times the surface

area of the gear in a one

minute period.
To summarize,

of steel provides the rapid

a proper

quench

must have control of the temperature

system
of the

cooling that is required to convert the austenite

quench media, adequate quenchant movement,

to hard martensite,

and consistent quenchantchemistry

The prime factors

that

determine the quench speed required are steel

chemistry,

quenchant from boiling. (See Fig. 2).

and massive. Therefore, a complex gear also is

for press quenching

--

Fig. 2 - Temperatures during quenehinq.

part geometry and designed func-

tion of the part.

..

The Mechanics of the Press Quench

There are several manufacturers

of quench

presses, such as QPS, Inc., Gleason Works,

Too low a quench rate will result in soft

Inc., Klingelnberg.

Oerhkon

and Jenny

parts. Too high a quench fate may result in

Presses, to name just a few. All quench press

excessive distortion and cracking.

designs must incorporate

Quenching has three distinctive stages:

ty of" quench

I. Vapor blanket stage - Delta temperature

rate. quenchant

creates an insulating vapor in slow cooling.

2. Vapor transport stage - Liquid breaks

oil, variable

and pressures.

The various

either use pneumatics

pressure systems.

At this stage, the

flow

die holding

pressure, die contact points. and cyclic flow

takes place.

3. Liquid stage - Cooling is taking place by

quenchant

flow direction.

through the vapor barrier; rapid heat transfer

conduction and convection.

a sufficient quanti-

press designs

or hydraulics

for the

Our focus on a typical press quench operation wHl feature a press that uses hydraulics for

part temperature is above the boiling point of

mechanical

the quenchant, but the rate of flow prevents the

(See Fig. 3).

movements

and pressing

force.

L.IE. Jones
is rill! Manager of the
Technical & Manage
ment' Services Group.
Lindberg Heal Treating
Company. He is a
memeber of ASM. the
Aerospace Council
(SAEIAMC) and the
lntemaiionai Federaiion
of Hear Treaters and the
author arid editor of
numerous books and
papers OT! heat treating

and metellurgy.
M' ... RCH/~PRIL

19~'

33

Basically.

this type of quench press con-

sists of a very rigid rectangular-box

type con-

two' econds or so). Also, the lower die is camadjustable .. so the die rings can be rai ed or

struction. The base is a tank which acts as a

lowered to compensate

for a predetermined

reservoir for the quenching oil.

amount

dishing

]t

also serves

as a support for the lower die. The upper portion of the machine

contains

the upper die

of component

or camber.

(See Fig. 5),

The loading of the hot components

can be

ram assembly, hydraulic units, and the elecm-

either manual or robotic. The transfer mecha-

cal panel. The opening at the front allows full

nism is critical to assure a minimum of part

access for changing the upper dies; the lower

heat loss from the furnace

die table moves outward and inward

for load-

lathe

operation,

the component

to be

quenched is removed from a furnace (usually

II

die. The

of the gear at the time of enter-

ing the quench is a determining

ing and unloading.

During

temperature

factor of the

final gear size,

The press quenchant

ystem typically con-

pusher-type continuous or rotary-hearth-type),

sists of the holding tank within the press, an

and placed onto the lower die in the "out" posi-

external oil reservoir, circulation

tion. The automatic

exchanger,

cycle moves the loaded

pump, heal

and internal heating source. The

lower die as embly into the center section of

oil reservoir typicaUy holds one and one-half

the machine and centers the die location. Next,

to two times the holding capacity of the press

the upper ram assembly

itself. (See Fig. 6)..

descends,

with an

expander centering the pan just prior to the

Within the quenchant system, oil tempera-

inner and outer dies' location on their respec-

ture is maintained

tive pressure points. The inner die. outer die

during operation. The operating oil tempera-

and expander
pressure

havecompletely independent

controls, (See Fig. 4). A circular

guard completely

ture for most gear press quenching operations

is between 130F and 145F.

Centrol (If the Gear Press

encloses the upper dies to

form a quench chamber which is affixed to the

upper ram for movement.

The chamber fills

with oil flow from the lower die once the dies

within 5F plus or minus

Quenching
This review

Process

of the control

process

focus on carburized, case-hardened

will

gears due

are in position. A variation in oil flow is con-

to their high susceptibility to distortion, When

trolled

examining

a press quenching

unique feature is the ability to pul: ethe various

sideration

must be given to part geometry,

die components

chemistry of the component and the volumetric

by three solenoid

valves.

Another

(that is, maintain die contact

on the component and cycle the pressure every

operation,

COI1-

change resulting from the hardening process ..

Also, it must be remembered

that the quench

pressing operation will only round up and f13.Iten the hot plastic gear. but will not change
tooth shapes. With this in mind, it is imperative
that the gear's prior manufacturing

operations

are closely controlled to assure consistent press

quench results. The gear coming out of the
pre s operation can only be as good as the gear
going in, The variables that must be controlled
before heat treatment are:
Gear material composition,
Grain direction and size,
Prior thermal processing (normalizing).
Machine stock removal,
Cold work. stresses,
Tolerances and sizes of reference surfaces.
Once the gear enters the heat treat process,
-----

fig. 3 - Schematic - lypical quench press.

34

(JEA~

TECHNOLOGV

the procedures
repeatable

employed must be consistent.

and closely controlled.

The vari-

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working longer t an a
attery-powered rabbit?

An ad in Gear Technology.
Better than 90% of our readers say they keep and refer to back issues of Gear Technology.
Your ad in our pages is seen again and again.

Give your product or service manum exposure in Gear Technology.

Call 18004518166
to find out how.

ables that must be controlled

in caJ'burizing

Temperature uniformity,

are:
Furnace temperature uniformity for heat-

ing rates and temperature distribution,

Control surface carbon content and repeat Gear fixturing during carburizing,

Atmosphere control or consistent stop-off

from the furnace

Gear handling

to the

press: Pickup contact and transfer time .

Coating rates after carburizing,

of temperature,

Time at temperature.
Fixturing and furnace loading,
procedures for surface integrity,

able diffusion gradients,

Repeatability

trol of:

uniformity,

time at temperature and control cooling rates if

annealing operations are used.
The reheating operation requires clo e con-

To successfully

operate thistype of press

quench, the factors must be regulated:

Quality of quench oil supplied,
Duration of quenching,
Quench oil temperature,

Pressure

Direction of quench oil flow.

Pressure applied to hold the component,
Location of component holding points.
In setting

up tbis ki nd of press quench

machine for operation,

it is well recognized

that the actual pressures

must be developed
trial and error.

and lime setting

for each eornponem

The following

by

are general

guidelines:
I. A fast quench or high oil flow is favored
in the first stage to reduce the temperature
the part to the transformation

of

range as quickly

as possible. However. the flexibility available

in the choice of duration and amount of oil
flow permits a compromise

between the need

for a fast quench to ensure satisfactory

ening response and the desirability
fig. 4 - Die systems and ram pressure.

hard-

of a slow-

er quench to minimize distortion.

2, The low flow rate in the second stage
allows the temperature

through

the various

cross sections to equalize. Thus, further cooling and marten sitic transformation

takes

place with reduced internal stresses.

3. The third state returns to high oil flow
when the component
transformation.

has nearly completed!

The high quenchant flow rate

cools the part for operator handling.

4. In setting the pressures for the inner and
outer dies, it is recommended

that minimum

levels be used. Use only the amount of pressure necessary

to true up the component

(high pressure settings can result in excessive

) I

distortions).
The variables within the acnial press operaAdjusting CAM for dish and camber

tion are:
Die contact,
Die oil flow,

Fig. 5 -lower

36

GEAR.

quench die systems.

TECHNOLOGY

Oil flow rate and Delta temperature,

 Smooth movement of lower table,

'\

Die closure rate,

Consistent ram pressure on all die rings,

Tempature

\-------,----,-,

If pulse pressure is used, repeatable time

for on and off cycles,
Tooling car,e - nicks. burrs, scale or dirt
should be avoided so nor to interfere with the
mechanical truing,
The control. of gear press quenching operations cannot be i elated for control of gear distortion.

The final results of the process

are

dependent on all prior operations, Therefore. if

the gear manufacturing

r-----t--

."..,,&~~.

L -O~e'iters
"

~'?:

process is well docu-

Jl

mented, and the overall process is in control.

Outlet

Drain

from the raw material stage to press quenching

Oil Reservoir

operation, repeatable results will be achieved

0\

with predictable size changes.

Gear Press Quench Instrumentation

As the demand

Pump

today's industrial quality

On

systems and the need for system documenta-

Fig. 6 - Quenching recirculation

svstem.

tion and repeatability inerea e, more interest in

press instrumentation

systems is being generat-

ed. To date, development

of instrumentation

systems for press quenching has ranged from

mechanical gauge

to complex computer inte-

grated systems. However simple or complex

the instrumentation

is, the Information collect-

ed must be analyzed and correlated to the overall prior manufacturing process to gain control
of the quench press operation.
A completeinsnumentarion

system will

document the following:

The location of the lower table,
Time measurement

of the cycles indicat-

ing travel time, air lockup, cycle delay,

troke,

cycle quench on, pulse on and off,

Linear measurement of stroke movement,
Quenchant flow rate,
Quenehant oil. temperature control,
Quenchant Delta temperature through the
die chamber,

----------

Fig. 1-1ypical

die and quench chamber.

-------

quench operation

can be made on-line, thus

Hydraulic system pressure,

reducing rejected parts and increasing the pre-

Die position indicators.

dictability of the final as heat treat size,

Non-contact temperature sensing of part

temperature entransfer,
Hydraulic sensitivity for dimensional

Aeknowledgement: Presented at the SME Conference.

Heal Treating of Gears, August 26. 1993. Livonia. MI.
/993_ Reprinted wid: permission.

measurement of the gear,

.' Contact sensing device for measurement
of part cooling rate,
With tabulation
immediate

of the above

analysis, adjustments

data and

to the press
MARCH/APRll1990

37