#: locale=en ## Tour ### Description ### Title tour.name = Forest City Gear ## Skin ### Label Label_AF109B0D_BB8F_F241_41E5_6CB2A7430B05.text = click & drag to view more ## Media ### Title map_9960D166_BC88_2EC3_41E3_BD96F5E1BD98.label = Roscoe Works map_A784A897_B210_D8A4_41C5_E9598BFBC267.label = Forest City Gear panorama_1020A090_2A1A_3C36_4190_0CF8A3BB87CC.label = Shipping panorama_102291C8_2BE6_5C16_41BC_219AD35144EE.label = Gear Shaping 3 panorama_1028A9DA_2A1A_CC2A_4189_7EE5265A9B24.label = Deburring panorama_1029524F_2A1E_5C2A_41AE_1B850BFFA855.label = Secondary NDT panorama_10302790_2A1E_C436_41A4_85A0A604DE2F.label = OD/ID Grinding panorama_1036C348_2A1A_3C16_41C4_4ABFADDE7B12.label = Warehouse 1 panorama_1047C14B_2A1A_3C2A_41BE_926D2841B568.label = Gear Grinding Pathway panorama_1058EDBE_2A1A_446A_41A6_A69A128DC83F.label = Warehouse 2 panorama_1059BD99_2A19_C436_41B4_35EE48664E53.label = Gear Grinding 1 panorama_10A69992_2BE7_CC3A_41C6_C1EE7791C4BC.label = Pathway 1 panorama_12551451_2A6E_4436_41A5_B21D41C36B28.label = Exterior - Back panorama_13A7B304_2A6E_DC1E_41A2_73E5F5A69EE3.label = Exterior panorama_13B0E774_2A6A_44FE_41AB_AB88BFD51C02.label = Lobby panorama_13B9E2F5_2A6E_5DFE_41C3_40959D98ED64.label = Roscoe Works - Exterior panorama_17E1B88D_2A6A_4C2E_41C2_3E9EDCE1EDB0.label = Exterior - Front panorama_6E30C964_2A2E_CC1E_41AB_9DA9A5D4BE7A.label = Secondary Pathway panorama_6E4AE106_2A2A_DC1A_41B7_11A9D2C60C19.label = Quality panorama_6E4D6F86_2A2F_C41A_41BE_8E0ACD59CC42.label = Hobbing 1 panorama_6E59EB58_2AEA_CC36_4140_6CABA56CE500.label = Gear Shaping 1 panorama_6E6B67DB_2BE9_C42A_41A6_9172E42DD5A8.label = Gear Shaping 2 panorama_6F4CDB55_2AE9_CC3E_41A7_5FBCBB411100.label = Roscoe Works 5 panorama_6F53D1D3_2AEA_3C3A_41B0_3E2702D1C09E.label = Roscoe Works 6 panorama_6F5D4409_2AEE_4416_41C2_F55B7D85EDFF.label = Roscoe Works 4 panorama_6F865A91_2A2E_4C36_41B9_4750A57CA215.label = Hobbing 3 panorama_6F8903FB_2A1A_43EA_41A8_96FDCEA931F4.label = Roscoe Works 2 panorama_6F8F1C63_2A1A_C41A_41B9_4CCE3D8BEA33.label = Roscoe Works 3 panorama_6FBE9475_2A2E_C4FE_41C4_93EB68EC4C7F.label = Hobbing 2 panorama_6FE41AB7_2A26_4C7A_41A5_0EA0399FB038.label = Roscoe Works: Mazak ## Popup ### Body htmlText_2929DE20_B210_DB9C_41CD_578EFF09A167.html =
Main and sub-spindle with live tooling
Y axis
.00005” offsets
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Main and sub-spindle with live tooling
Y axis
.00005” offsets
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Sunnen SH-4000
Sunnen SV1015
Sunnen SV1005
Speedfam Surface Lap
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Keyence 25 watt hybrid laser with rotary table capability
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FCG has two level II Technicians with plans to establish NADCAP certification by midyear 2022.
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5 OD/ID grinding machines
• (2) Kellenberger Kel-vista 175/1000 Universal OD/ID
• Usach 100-T4 ID Grinder
• (2) Okuma GA-26TII
• One equipped with Gosinger robot autoload cell with vision
Key Department Capabilities
• Ceramic and Dressable CBN wheel utilization
• Rotary diamond dressers
• In process gaging
• Renishaw probing
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Nital Etch capability for internal verification of grinding burns
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400 mm pitch diameter capacity x 72" length
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FCG has developed its turning and milling capabilities to control the more complex higher tolerance parts that are needed to yield high quality gears that our industries demand.
Facility shares all network and sever communication with the main plant
Facility is also completely climate controlled
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CNC flank crowning available executed via electronic guide while maintaining straight root zone
Independent lead modifications
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Gleason P500 ES
Gleason GP500 ES
Gleason P300 ES
Gleason GP300 ES
Gleason GP300 ES High Speed
Mitsubishi ST40 CNC
Bourn & Koch MS450
Key Department Capabilities
• Guideless Helical capability
• Direct drive work and cutter spindle for superior accuracy with no backlash
• CNC crowning – both radial and flank crowning
• Discrete lead modifications with independent flanks
• Face Gears
• Taper correction up to 10 deg
• Segment
• Alignments tolerances of 5 min
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Integrated dryers in each for redundancy
Networked for offline communication in the event of unit failure the other unit will come online to support demand
Variable drive for efficiency
Variable temperature cooling to allow for low speed operation and prevents excessive moisture
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(13) hobbing machines all with CNC control and most with flexible automation
• (5) Koepfer 200 CNC
• (3) Koepfer 160 CNC
• (1) Koepfer 300 CNC
• (1) Koepfer 153 CNC
• (2) Gleason 125GH
• (1) Monnier Zahner MZ 130
Key Department Capabilities
• High helix hob swivel
• Skiving alignment devices
• Mutli gear and multi hob dialogue programming
• Flexible automation for efficient setup of small run orders
• Two hob deburring
• High speed hob spindles
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Aqueous part washing
Vibratory Finishing with REM Superfinishing capability
Media blasting – Glass bead, soda, and aluminum oxide
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Kapp VX59
Kapp VUS55
Samputensili S375G
Hofler Helix 400 SK
Reishauer RZ410
Drake GS:TE-LM
Drake GS:G2-LM200 with Fanuc robot auto loader
Key Department Capabilities
• Internal / External grinding via dressable or CBN
• Dressable capabilities down to 25mm wheel diameter
• Generative grinding capability with RZ410 with flexible dresser option
• Thread forms not limited to ZI, ZK, ZN
• Special non-gear forms
• On board inspection
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(3) dedicated analytical Gear Inspection machines
• Klingelnberg P65
• Wenzel WGT350
• Wenzel WGT500
(3) CMM
• Zeiss Accura with rotary table and gear software
• Zeiss Contura
• Wenzel LH-87 with Gear Software
Approximately 30 Precision Gage Vari-Roll gages
(4) VariPC units with two being wireless and mobile
Digital Superficial hardness tester with “N” and “C” scale
Mitutoyo Surface Finish testing
Inventory of master gears, plug gages, reference pins
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Supplies clean grinding oil for Gear Grinding department – 4,300 gallon capacity
External chiller that manages grinding oil temperature with ambient temperature tracking
5 – 10 micron filtering capability
Redundant delivery pump design to reduce downtime risk
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Forest City Gear inventories and manages over 6,000 gear cutting tools that include hobs, shaper cutters, and milling cutters.
• Koepfer KFS-100
• Star PTG1
Key Department Capabilities
• Sharpen both Carbide and High Speed Steel
• Helical hob and helical step face shaper cutters
• Surface finish to 4 microinch
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CNC radial crowning available to produce lead crown with corresponding root radius
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5 OD/ID grinding machines
• (2) Kellenberger Kel-vista 175/600 Universal OD/ID
• Usach 100-T4 ID Grinder
• (2) Okuma GA-26TII
• One equipped with Gosinger robot autoload cell with vision
Key Department Capabilities
• Ceramic and Dressable CBN wheel utilization
• Rotary diamond dressers
• In process gaging
• Renishaw probing
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Full CNC with autoloading capabilities
Skiving alignment device to provide an alternative to Gear Grinding
Multiple gear with alignment programing in dialogue
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Integrated 4th axis
Tool probe
Renishaw Probe package
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High Speed 1500 stroke per minute capability
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Smooth Controls
Glass scales on X axis for higher accuracy
Live tooling
Y axis
High pressure coolant equipped
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1 machine equipped with bar feeder
Live tooling
High pressure coolant available
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Networked to the main plant and can be programmed offline
Vast XT scanning probe head
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Integrated 4th axis
Tool probe
Expanded memory
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