Ashoka has been a leader in manufacture of girth gears,Industrial Girth Gears, ring gears and sugar mill gears in single piece and multiple segment
castings and forging, since 1968. We employ modern techniques
for complete material selection, manufacturing process, enhance
performance reliability and overall life of the gears. The
expertise and experience of our engineers makes us capable of
providing any kind of open power transmission drive. We offer a
complete supply package, which includes gear casting, heat
treatment such as volume hardening, case carburizing, quenching
and other forms of heat treatment to sophisticated gear cutting
and precision grinding. There are many kind of open gears
suitable for various applications.
Upgraded with the latest technology, we use computer aided
designing and finite element analysis for the analysis of design
and structural integrity as well as ensure optimum life span of
gears. We make use of specialized material like Carbon Steel and
Alloy Steel in both cast and fabricated. Spheroidal Graphite
Iron (SG Iron), Bronze and other materials are analyzed for most
appropriate selection.
Various heat treatment techniques are also used to enhance the
surface as well as volume hardness of the material. The various
methods used for heat treatment are :
Chemical & Minerals Industry
- Volume Hardening
- Induction Hardening
- Case Carburizing
- Quenching
- Stress Relieving
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Our machines have a machining capability upto a 11.5
meters diameter on imported machines like WMW, NILES, MAAG,
TITAN, COLLET & ENGLEHART, BRADFORD etc. These machines
assure dimensional and surface tolerances in compliance with
AGMA and DIN quality standards and thus increasing the working
life of gears.
Our machines and gears undergo stringent quality checks which
include dimensional accuracy, metallurgical testing and
analysis, mechanical as well as physical testing and other
non-destructive inspections. We ensure that proper contact on
the tooth flanks of both the girth gear and pinion is maintained
between the teeth for optimal meshing. We use various tools like
VERNIER CALIPERS, MICROMETERS, TOOTH VERNIERS, GUAGES, DIGITAL
READOUTS, EQUOTIP HARDNESS TESTERS etc., for checking the
dimensions of these Gears.
Type of non-destructive testing includes:
- CHEMICAL COMPOSITION ANALYSIS
- MECHANICAL (PHYSICAL) ANALYSIS
- MAGNETIC PARTICLE TESTING
- DEVELOPER PENERATION TESTING (DP TEST)
- HARDNESS TEST
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We also provide lifetime technical support and after
sales service, irrespective of the guarantee periods. For areas
where our offices are not present, like in cases of
international clients, local agents assist them, depending upon
the region of installation and extent of service required.
Moreover, 24x7 service mobile number is provided to all clients
for urgent help required.
Materials Used
Selection of a suitable gear material is extremely important
and hence we manufacture gears to achieve their intended
performance, life and reliability. Gears with high load capacity
require a hard material which is not easy to machine. On the
other hand, high precision favors materials are easy to machine
and hence require material with lower strength and hardness
ratings. Light in weight and small size favors light non-ferrous
materials, while high capacity requires the opposite. Thus,
trade-offs and compromise are required to achieve an optimum
design.
Ferrous metals are widely used for manufacturing gears, though
many non-ferrous & light-weight metals and even plastics are
also used for their manufacturing. The designers have myriad of
choices, which are based upon an understanding of material
properties and application requirements.
The ferrous metals are used for manufacturing of gears owing to
their high strength, good 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 advantageous as it saves machining costs by
molding the gear blank. It also has high tensile & yield
strengths and is excellent under dynamic conditions, thus
providing excellent internal damping properties.
Steel is another material that is used for manufacturing gears.
Divided into two main division Carbon Steels and Alloy Steels,
these gears have unique individual features. The carbon steel is
low cost, reasonable, easy to machine and has the ability to be
easily harden. These steels are less resistant to corrosion and
hence are not readily used.
Alloy Steel consists of various low grade alloys that offer
high strengths. These alloy steels have a wide range of heat
treatment properties that make the category of alloy steels the
most versatile.
Stainless Steels is rarely used for manufacturing gears. Only
special purpose gears are manufactured using stainless steel
owing to the high cost involved. The 300 series true stainless
steel is resistant to all the corrosive conditions and the 400
series steel is comparatively less corrosion resistant.
We manufacture gears after extensive research & analysis
and detailed categorization of material. Complying with various
industrial standards, we develop gears keeping in mind the
specific properties and applications. Chemical composition,
mechanical properties, material hardness, heat treatments etc.
are considered before selecting material for manufacturing of
gears.
At Ashoka, various internationally recognized standards like
DIN (German), ASTM (American), AISI (American), BS (British), IS
(Indian) are followed to develop products according to the
specific needs of our clients. The following are some of the
standards that are most widely used for gearing applications:
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