To mate with active gears under operation, we also offer Pinions and Shafts, which are manufactured in compliance with client's specific designs. All that is requisite for the high-fidelity manufacturing of these products is the artwork of fabricating, which alleviate the products' contact with gear under operations. Installation services are also rendered by us along with the supplying facilities. The Pinions and Shafts we offer are fabricated with special forged steels with particular alloys. The utilization of toughened as well as tempered materials also furnish them a requisite strength as well as mechanical attributes whereas tight endurance profile machining & grinding gives accuracy and efficiency.
- Capacity: Up to 6500mm Length, 600mm Diameter
- Form: Integral & Shrunken fit Pinion Shafts
Common Applications: These are applicative in various equipments, which are employed in industrial spheres like Sugar Mills, Thermal Power Station, Fertilizer Plants, Cement Plants, Steel Rolling Plants, Textile Plants, Machine Tools Material Handing Equipment, Paper Mills, Mining Industry, Sponge Iron Plants, Mineral Plants, Chemical Plants etc.
Finite Element Analysis: ASHOKA as one of the stellar Ring Gear Manufacturers In India, can also provide stress analysis and load analysis on the gears and pinions employing finite element analysis so as to check for proper assortment of the materials and geometric designs.
Reverse Engineering and Designing: In case it is favorable to transport the gears to our manufacturing facility inverse engineering and designing is moved out to yield the drawings precisely as per illustration. In most cases the activity is also loaded on to the applicable machines so as to receive accurate geometrical sizing.
Gear Inspections: Gear inspections are carried with utilizing specific hand, mechanical and automated tools and testers factory-made by celebrated companies such as MITOTOYO etc. Different checks including material tests, dimensional measures such as mechanical testing, chemical testing and hardness testing. Nondestructive experiment for intrinsic imperfections includes magnetic particle inspections (MPI) and ultrasonic testing (UST). Surface crack spying involves developer penetrant testing (DP).
Gear tooth profiles are patterned and checked by using particular instruments such as profiles testers and vernier calibers. Comely contact on the tooth formations of both the girth gear and pinion is examined to insure optimum meshing process.
Stage wise reviews at our company are carried out at different stages of production for which an absolute check log in well-kept for remark. the agencies of third party inspections such as SGS, DNV, LLOYDS, TPL, MOODY etc. have often met our factory for perceiving of above tests and sequent qualitative clearance of the several jobs. We welcome all third party inspection agencies in all possible cases.
On Site Installation: As the manufacturer company of pinions shafts in India, we offer management of on-site installation of the girth gears. A supervision adept is deputed to the location, nevertheless, installation tools/tackles, local manpower and lifting tools such as portable cranes etc. are to be given by the client. For the special cases, we ASHOKA in India, may also take up the total activity of mill installment and authorization including all of the above but that depends on the geographical position of the site.
After Sales Support: After sales technical support provided by ASHOKA, have all the solutions for gears and pinions supplied by the company. The support involves services regardless of guarantee period of the provided item. On-site support is supplied on chargeable basis.
Gear Designing: Complete dimensional reviews are finished on the existing gear at location so as to acquire detailed manufacturing mill drawings for production. Inspections also consider drilled chips assemblage (if needed and possible) for chemical investigation and hardness tests.
Material Selection: A proper mill grade of material in steels (alloy steels and carbon steels), irons (including ranked irons, SG iron etc.) or bronze (in general phosphorus bronze) is chosen based on the needed mechanical properties in case the selfsame is not specified by the customer. We give gears and pinions in cast and forged varieties. Different international mill material regulations are utilized including AISI (USA), BS (British), JIS (Japanese), GS (German), ASTM (USA), IS (Indian) standards.
Castings & Fabrication: Casting or forging is bring forth by keeping minimal essential machining adjustments on all relevant and needed faces and surfaces. The casting/forging is volume heat activated in the mill particular enclosed furnaces with comely temperature controls for achieving the wanted mechanical properties. Chemical testing is executed by utilizing current spectrometers, mechanical attributes traced from test pieces employing universal testing machines and hardness received using equotip kind hardness testers.
Non destructive testing to find internal and surface defects including Magnetic Particle Inspection (MPI) is moved in the mill after the casting is heat treated and set for machining, where as, Ultrasonic Testing (UST) is executed after proof machining of the job for high-fidelity results.
Facing: Combined facing is carried out on every girth / split gear on each side of conjuncts on the two halves on particular horizontal floor borers (UNION, SKODA). Befitting machining allowance is maintained for finish machining in case further heat management is to be carried out, which may appoint distortion on the job and hence fluctuation in the sizes. In all those cases finish machining is executed after the initial turning and heat treatment and in few cases even after single round of teeth cutting.
Turning: After the procedure of joint facing the job is inverted on particular vertical turret lathes (FRORIEP, DORRIES, BERTHIEZ). Correspondent to the joint facing operation befitting machining share is kept for finish device in case further heat treatment is to be executed that may charge impairment on the job and hence unsuitable alteration in the sizes. In all such occurrences finish machining is executed after the finish joint facing and heat treatment processes.
Gear Cutting: After the finish turning of the girth gear it is the teeth cut activity that is executed by utilizing particular hobbing devices (WMW, MAAG). In most cases teeth cutting in the mill is finished in more than double cuts- one for roughing during which major clod of the metal is shredded and the other for completion during which processed size is kept up. Mostly, stresses are formulated during teeth cutting due to the big volume of metal that is cut and thence the job is inflection relieved after the basic (rough) cut. The activity is also opened for a calculated time period for it to expand or shrink to the maximal extent preceding to the finish cut.
Heat Treatments: Assorted varieties of heat treatments are executed on gears/pinions. All jobs are volume treated at the casting or forging phase. As needed on a case to case base the gears are heat treated once again to alleviate accents rendered during machining. In some case if consistency needed is more (in the ambit of 400-550 BHN) the jobs may be induction toughened on the surface parts where advanced hardness is compulsory. Other kinds of hardening include nitirding and case carborizing, which are also surface hardening methods analogous to induction hardening. Jobs are also oil/polymer quelled as hardening so as to control and hold out the needful range of hardness.
Following are the different types of heat treatments that are offered:
- Case carburizing
- Volume hardening
- Induction hardening
- Stress Relieving