Gears Manufacturing Procedure

Gears, Pinions & Shafts offered by us include Mill Girth Gears, Ring Gears, Bull Gears, Sugar Mill Gears, Fabricated Gears, Worm Gears, Ground Gears and Pinions & Shafts. As industry leaders in our area of operations, we provide production support in single piece and multiple segments. Further, for large gears, we manufacture these in castings and in fabrication support using special ring rolled forged rims.

Here, the use of state-of-the-art technology support also allow us to maintain precision standards in involved designing, material selection and manufacturing processes, thus providing for a much enhanced performance, process reliability as well as service life of the industrial gears and pinions offered from our end. Further, our rich industry experience also allows us to engineer complete solutions for any type of open power transmission drive.

Some of the industry sectors these are used in include steel plants, mineral grinding & processing plants, cement plants, power plants and others.

Gears Manufacturing Procedure

Gears Manufacturing Procedure employed at our end is backed by latest technology based processes followed in the industry so as to ensure flawless performance support of the solutions being offered. With our expertise in offering gear solutions in single piece/multiple segments as well as in castings and special ring rolled forged rim fabrication, the production steps employed at our end include:

Site Audit & Gear Inspection :

Condition of girth gear evaluated at site on basis of remaining working life of gears
Offering recommendations on existing gear life as well as requirement of new gear as per audit findings

Gear Designing :

Carrying out complete dimensional inspections on existing gear on-site for developing detailed manufacturing drawings for production
Inspections done also comprise drilled chips collection (if required and possible) for carrying out hardness and chemical analysis tests

Material Selection :

Selection of appropriate grade of steel (alloy steel and carbon steel), iron (including graded iron, SG iron) or bronze (phosphorus bronze) done based on required mechanical properties
Providing gears & pinions in cast and forged forms
Can be made available in different international material standards including JIS (Japanese), GS (German), ASTM (USA), AISI (USA), BS (British), IS (Indian) standards

Castings & Fabrication:

Casting/forging produced by maintaining minimum necessary machining allowances on relevant/required faces and surfaces
Volume heat treatment of casting/forging in special enclosed furnaces using proper temperature controls that assists in attaining desired mechanical properties
Chemical testing done using latest spectrometers
Mechanical properties arrived at by using test pieces using universal testing machines
Hardness obtained using equotip type hardness testers
Non destructive testing also carried out for detection of internal & surface flaws
Magnetic Particle Inspection (MPI) carried out post heat treatment of casting and when it is ready for machining
Ultrasonic Testing (UST) carried out after proof machining of job for accurate results

Facing :

Joint facing carried out on all girth/split gears on both sides of joints
It is done on two halves on special horizontal floor borers (UNION, SKODA)
Appropriate machining allowance maintained for finish machining in cases where further heat treatment is required and done and the process may create distortion on job/variation in sizes
In such cases, finish machining done post preliminary turning and heat treatment
In some cases, it is done even after one round of teeth cutting

Turning :

Post joint facing, job is turned on special vertical turret lathes (FRORIEP, BERTHIEZ, DORRIES)
With process similar to joint facing operations, here appropriate machining allowance is maintained for finish machining to accommodate further heat treatment needed to be carried out which may create distortion on job/variation in sizes
In these type of cases, finish machining done post heat treatment and finish joint facing

Gear Cutting :

On finish turning of gear it is teeth cut through use of special hobbing machines (WMW, MAAG)
In most cases, teeth cutting carried out in more than two cuts- one for roughing where major chunk of metal is cut and other for finishing with maintenance of finished size
Normally stresses developed during teeth cutting due to large volume of metal cut and hence job is stress relieved post first (rough) cut
Job also opened for calculated time period for it to expand/contract to maximum prior to finish cut

Heat Treatments :

Different heat treatment options performed on gears/pinions
All jobs volume hardened at casting/forging stage
As required in case to case basis, gears are heat treated again for relieving them for stresses generated during machining stage
In cases where more hardness is required (in range of 400-550 BHN), jobs may be induction hardened on surface portions where high hardness is desired
Other options of hardening used include nitirding and case carborizing
Jobs oil/polymer quenched at tempering for controlling and maintaining required hardness range

The following various types of heat treatments offered :

Volume hardening
Induction hardening
Case carburizing
Nitriding
Stress Relieving

Gear Inspections :

Gear inspections carried using special hand, mechanical and automatic instruments and testers of renowned brands like MITOTOYO
Different checks like dimensional measurements, material tests like hardness testing, chemical testing, mechanical testing carried out for seeing the flawless finish of the products
Non destructive testing also carried out for internal flaws including ultrasonic testing (UST) & magnetic particle inspections (MPI)
Surface crack detection is carried out using developer penetrant testing (DP) method
Gear tooth profiles checked using instruments like Vernier Calipers and profiles testers
Proper contact on tooth flanks of both girth gear and pinion checked for ensuring optimal meshing between teeth
Carrying out stage wise inspections at various stages of production with complete check log maintained for reference purposes
Visits of Third party inspections agencies like LLOYDS, SGS, DNV, TPL, MOODY for witnessing above tests as well as subsequent qualitative clearance of respective jobs
We welcome any third party inspection agency in all cases

Computer Aided Designing :

Here, we make use of advanced computerized design generation software like AUTOCAD, SOLID WORKS and others for providing accurate designing support for gears and pinions
With all software updated to latest versions, we are also able to carry out precise interference checks and dimensional accuracies
This facility allows us to efficiently work with client designs and drawings as well as provide suggestive feedback to clients for possible improvement of designs

Finite Element Analysis :

Here, our expertise lies in offering load analysis and stress analysis on gears and pinions
Finite element analysis also allows us to check for appropriate selection of materials as well as geometrical designs used

Reverse Engineering and Designing :

Reverse engineering & designing is used by us for generating drawings exactly as per sample

On Site Installation :

We offer supervision of on-site installation of gears and pinions manufactured by us
For this, supervision expert is deputed to site with support like lifting equipment like movable cranes, local manpower, installation tools/tackles provided by clients
In special cases, we may also take up entire installation and commissioning (depending upon geographical location of site)

After Sales Support :

Offering lifetime after sales technical support to customers for gears and pinions supplied by company
Support includes services irrespective of guarantee period of supplied item
On-site support also provided on chargeable basis