Gears & Pinions

4,20,000

Cement Plant Manufacturers India – TURNKEY PROJECTS

ASHOKA has been a market leader in manufacturing of various type of girth gears, ring gears, bull gears and sugar mill gears manufactured in single piece castings and in multiple segments for rotary equipment applications such as ball mills, sag mills, kilns, coolers, dryers, scrubbers etc. and enclosed drives. Comprehensive expertise and vast experience enables us to manufacture open gearing and refurbishing of enclosed gear drives to high level of accuracy suiting international standards. We have state-of-the-art machining capability to enhance performance, reliability and overall lifetime of our gears. Large gears are manufactured in special alloy grade castings as well as fabricated with special ring rolled alloy steel forged rims. Various forms and types of heat treatments such as volume hardening, case carburizing, quenching and other forms of surface heat treatment such as induction hardening and flame hardening is also undertaken to enhance material wear properties.

Request Consultation Call

MATERIAL SELECTION

General 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.

Cast Irons (SG Iron)

Cast Iron’s in various grades are 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. Cast Iron is supplied in various forms and grades out of which SG Iron is a commonly used grade for large gears.

Carbon & Alloy Steels

Steels are divided into two main divisions: plain Carbon Steels and Alloy Steels. 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. 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.

Material Standards

ASHOKA offers castings and forging as per various international standards including:
• ASTM & AISI (USA),
• BS (British),
• JIS (Japanese),
• GS (German),
• IS (Indian) standards.

Project Range

TYPE	MACHINING CAPACITY	APPLICATION
SPLIT / GIRTH GEARS	8.5 m Dia x 50 Module	Ball mills, rod mills, SAG mills, rotary kilns, rotary coolers, rotary dryers, scrubbers, stacker reclaimers, for cement plants, power plants, steel plants, mineral grinding & processing plants etc.
SUGAR MILL GEARS	8.5 m Dia x 50 Module	Crushing mills, sugar dryers, crystallizers for sugar plants
BULL GEARS	5.0 m Dia x 50 Module	Ball mills, rod mills, SAG mills, rotary kilns, rotary coolers, crusher mills, mining, steel plants, power plants, paper plants, fertilizer plants, grinding applications, heavy machinery etc.
WORM GEARS	4.0 m Dia x 40 Module	Gear reducers, open gearing for various industrial sectors specified above
PROFILE GROUND GEARS	2.5 m Dia x 28 Module	Gear reducers, machine tools and various other applications for above specified industrial sectors.
PINION & PINION SHAFTS	1.5 m Dia x 55 Module	Gear reducers, machine tools and various other applications for above specified industrial sectors.
HERRINGBONE GEARS	3.5 m Dia x 40 Module	Power presses, machine tools and special purpose machines.

The above projects can be undertaken with a scope of supply including pre-feasibility and feasibility analysis, basic & detailed project engineering, equipment supply, site erection and commissioning and operational site training of working personnel.
Complete civil drawings and designs are provided to the client for undertaking civil works at site.

Frequently Asked Questions

1. What industries do your services cater to?

We primarily serve the oil & gas, energy, and resource extraction industries. Our expertise spans exploration, offshore drilling, processing management, and asset maintenance, making us a comprehensive partner for end-to-end operations.

2. How do you ensure safety during offshore drilling operations?

We follow strict international safety standards, implement advanced monitoring systems, and conduct regular risk assessments. Our teams are trained in emergency response and operational best practices to ensure safe and efficient drilling in complex environments.

3. What technologies do you use for exploration and site development?

We utilize modern tools such as seismic imaging, geological modeling, and data analytics to assess site viability and resource potential. These technologies help us make informed decisions and optimize development strategies.

4. How do you improve processing efficiency?

We enhance efficiency by optimizing system design, integrating automation, and continuously monitoring performance. This allows us to increase output, reduce waste, and maintain consistent product quality while adhering to safety standards.

5. What is included in your maintenance and asset integrity services?

Our services include preventive and predictive maintenance, real-time equipment monitoring, inspections, and lifecycle management. These measures help reduce downtime, extend asset life, and ensure reliable long-term operations.