Heavy Duty Industrial Gears

Computer aided designing and finite element analysis is utilized for analysis of design and structural integrity of the gears to ensure optimum life span. Specialized gear materials in Carbon Steel and Alloy Steel, both cast and fabricated, Spheroidal Graphite Iron (SG Iron), Bronze and other materials are analyzed for most appropriate selection.

Heat treatment techniques to increase higher surface hardness and volume hardness of the material are carried out. The different types of heat treatment techniques include the following:

Chemical & Minerals Industry

• Volume Hardening
• Induction Hardening
• Case Carburizing
• Quenching
• Stress Relieving

Machining capabilities to machine upto a 11.5 meters diameter gear on branded imported machines such WMW, NILES, MAAG, TITAN, COLLET & ENGLEHART, BRADFORD and others ensures proper dimensional and surface tolerances as per AGMA and DIN quality standards which extend the working life of gears.

Some of the branded machines used for producing large diameter gears are as follows:

Inspection and testing facilities include dimensional checks, metallurgical testing and analysis, mechanical (physical) testing, other non-destructive and gear tooth inspections. Proper contact on the tooth flanks of both the girth gear and pinion is checked to ensure optimal meshing between the teeth. All dimensions are checked by standard VERNIER CALIPERS, MICROMETERS, TOOTH VERNIERS, GUAGES, DIGITAL READOUTS, EQUOTIP HARDNESS TESTERS etc.

Type of non-destructive testing includes CHEMICAL COMPOSITION ANALYSIS on Spectrometers, MECHANICAL (PHYSICAL) ANALYSIS, MAGNETIC PARTICLE TESTING, DEVELOPER PENERATION TESTING (DP TEST), HARDNESS TEST etc.

Lifetime technical support and after sales services are provided at all times no matter how old the gear or pinion. This supports includes services irrespective of the guarantee periods. For international clients local agents may assist in providing services depending upon the region of installation and extent of service required. A 24x7 service mobile number is provided to all clients for urgent help required.

Gear Materials
In order for gears to achieve their intended performance, life and reliability, the selection of a suitable gear material is very important. Often not all design requirements are compatible. High load capacity requires a tough, hard material which is difficult to machine; whereas high precision favors materials that are easy to machine and, therefore, have lower strength and hardness ratings. Light weight and small size favors light non-ferrous materials, while high capacity requires the opposite. Thus, tradeoffs and compromise are required to achieve an optimum design.

Gear materials vary widely, ranging from ferrous metals, through many non-ferrous and light-weight metals, to various plastics. The gear designer and user faces a myriad of choices. The final selection should be based upon an understanding of material properties and application requirements.

Ferrous Metals
Despite the introduction of many new exotic metals and plastics with impressive characteristics, ferrous metals are still the most widely used for gears, because they offer high strength, response to heat treatment and low cost. Cast iron and steel, carbon steels and alloy steels are in common use for gearing applications.

Cast Iron is widely used for large gears where it is advantageous to save machining costs by molding the gear blank. Cast steels also offer this advantage together with higher tensile and yield strengths, but cast iron is superior under dynamic conditions, providing excellent internal damping properties.

Steels are divided into two main divisions: plain Carbon Steels and Alloy Steels. The carbon steels offer low cost, reasonably easy machining and ability to be hardened. A major disadvantage is the lack of resistance to corrosion. When elements other than carbon are added to the iron, the steel is termed "alloy steel". These cover a wide range from low-grade types to special high alloys offering exceptionally high strengths. Alloy steels offer a wide range of heat treatment properties that makes the category of alloy steels the most versatile.

Stainless steels are contained within this large category even though it is sparingly used and only for specific applications due to the high cost factor. Stainless Steels are divided into two types: the so called 300 series true stainless steels, which resist nearly all corrosive conditions; and the 400 series, which although not truly stainless, offer less corrosion resistance only in certain environments (such as certain acids and salt water) and are otherwise considered stainless.

After extensive research and analysis, detailed categorization of materials has been developed over the years by various organizations and countries. Today, there are hundreds and thousands of material standards followed all over the world. Each standard is developed keeping in mind specific properties and applications. These standards provide details on chemical composition, mechanical properties, material hardness, heat treatments etc. to be achieved for attainment of desired specified properties.

At Ashoka we follow various internationally recognized and commonly used series of material standards including DIN (German), ASTM (American), AISI (American), BS (British), IS (Indian) standards. The following are some of the standards that are most widely used for gearing applications:

Commonly Used Material Standards

Product	Type Of Application	Material Used
Large Gears
Precision Gears