Internship Report FINAL

Study of processes involved in manufacturing of high speed gear TM3G3489
1.0 COMPANY PROFILE
Triveni Engineering & Industries Limited is a focused, growing corporation having core
competencies in the areas of sugar and engineering. The Company is one amongst the largest sugar
manufacturers in India and the market leader in its engineering businesses comprising high speed
gears, gearboxes, and water treatment solutions.
With 7 sugar mills, 6 co-generation units and 1 distillery spread over 8 locations in Uttar Pradesh,
we progressively engage with over 250,000 farmers through our cane marketing and development
programs.
As the largest Indian manufacturer of high-speed and niche low speed gears and gearboxes,
Triveni commands a dominant market-share in the gears market in the region. As a focused player
in water treatment domain, we offer end-to-end services & product mix in the technology spectrum
of water and waste water treatment. We have a dedicated manufacturing and R&D unit each for
Gear and Water Treatment Applications at Mysore and Noida respectively.
Our two major business segments – sugar and engineering - are mutually exclusive in terms of
growth factors and environment. The sugar business is immune to the upheavals in the global
economy, and is dependent only on the sugar cycle. Our engineering businesses cater to the two
most critical industries – power and water.
Our steam turbine business, located at Bangalore has been demerged through a scheme of
arrangement into Triveni Turbine Limited (TTL) from the appointed date on 1st October 2010, and
the same has become effective w.e.f. 21st April, 2011. Triveni Engineering & Industries Limited
holds 21.8% equity capital of Triveni Turbine Limited
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2.0 BUSSINESS OVERVIEW
Triveni Gears, Gear Business Group of Triveni Engineering & Industries Ltd., is the largest
manufacturer of high speed gears and gearboxes in India for steam turbines, gas turbines,
compressors, pumps, blowers as well as special purpose industry applications designed as per API,
AGMA. DIN, ISO and other international standards. Triveni Gears also manufactures niche low
speed gearboxes for mini Hydel turbines, Steel mills, sugar mills, rubber mixers and extruders,
cement mills. Thermal plants and plastics etc.
Reliability built through superior technology, manufacturing and product quality combined with 38
years of rich experience in high technology gears are our key strengths that lead to develop
customized gear drives, meeting tough demands of Industries across high speed as well as Niche
slow speed applications.
Triveni Gears offers end-to-end solutions in high-speed gears and gearboxes. Started in 1976, with
the objective to fulfil the Company's captive demand for high-speed gears, over these years, it has
become the dominant supplier to all major OEMs in the country. With unmatched capabilities in
the design and development of all types of gears and gearboxes, combined with an ultra-modern
manufacturing facility the Company is poised to "Gear the Future".
Triveni Gears and Lufkin Industries, LLC (part of GE-Oil & Gas) joined hands, way back in the
year 1998 through strategic technology license agreement to redefine gear transmission technology
in India. Over the last decade and a half, the technology license from Lufkin has been expanded
with respect to product range, applications and geographies, now designated to countries in South
East Asia, parts of Africa and South Asia.
Lufkin has been a world leader in high speed gear applications as well as Niche low speed and has
been in the field of gears for over a century. Lufkin's commitment to excellence has been
supported by an extensive research and development as well as modernization programme.
Customers worldwide depend on Lufkin for their continuous commitment to technological
innovation and engineering experience in mechanical transmission. Superior product technology
coupled with rich experience of Lufkin and combined with exceptional problem solving
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capabilities allows Triveni Gears to produce customized Gear drives which meet the tough quality
and specification demands of the industry.
License agreement would include technology transfer from design, manufacturing and service for
new build and aftermarket coupled with technical support and training to Triveni Gear's personnel.
While Triveni Gears manufactures gearboxes for (below 7.5 MW applications using its own
technology, and the license covers above 7.5MW) all high speed and niche low speed applications.
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3.0 MILESTONES
 2014
Supplied 15MW test rig gearbox for testing 1000MW capacity generator
Frame6 load gearbox order from USA
27680 rpm drop in replacement of integrally geared API 613 gearbox for a refinery in SE Asia
Won CII EXIM Bank Award second year in row for Business Excellence 2014 – Strong
commitment to Excel
 2013
New Product Development – 850 KW Planetary Gearbox supplied for sugar mill drive application
Commissioned for first time indigenously manufactured drop-in replacement unit for LM6000 Gas
Turbine load gearbox for India's leading petrochemical company.
OHSAS 18001 certified
Won CII EXIM Bank Award for Business Excellence 2013 – Strong commitment to Excel
 2012
Exclusive MOU with BHEL signed for gas turbine Load gears
CE Certification
Went Live on SAP across all functions
Implemented 5S and Kaizen
 2011
Highest power local gearbox for 38MW for India's largest automobile company
Highest API-613 30 MW gearbox for the largest petroleum refinery
Highest 70,000 RPM gearbox for defense test rig
Renewal of High Speed license agreement with Lufkin for another 12 years, includes Gas Turbine
Load gears and ASEAN countries as additional territories, and local manufacturing up to 62 MW
Signing of LSLA with Lufkin for Metal & Steel, Rubber & Plastics
Commissioning of 1.6 MW fully instrumented Test Rig for testing of high power upto 90MW
gearboxes- exclusive Test facility in India.
 2010
Long term strategy and visioning Plant upgraded to manufacture and handle 2 meter dia gears
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 2009
First locally manufactured drop-in replacement of Frame-6 gear box at for India's leading
petrochemical company
 2008
CFT training on high power high speed technology at Lufkin-US
First order for SE Asian palm oil market in Indonesia Kaltimex
Balance score card PMS implemented
 2007
Establishment of global supply chain for raw- materials
First lot of gear sets shipped to a leading engineering company in Germany for 20MW geared fluid
coupling
Setting up of full fledged in-house metallurgical testing facility
First high power 6 MW vertical offset hybrid configuration for Hydro turbine
 2006
Retro fit of High power Gas Turbine Load Gearboxes at ASEB and GEB
Development of first integrally geared 37935 rpm compressor indigenously

designed/manufactured gearbox for a public sector engineering conglomerate
 2005
Renewal of High speed agreement and with enhanced local manufacturing up to 25MW & added
geographies
CNC hobbing and profile grinding technology adopted
Retro fit of vertical roller mill for Cement Segment
Plant layout optimization, technology and infrastructure up gradation
 2004
Competency mapping and development through one of the leading HR consulting companies
 2003
Hydel technology training at France Visioning and Six Sigma initiative
 2002
First export supply to Singapore of API Gearboxes
 2001
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Retro fit of 25 MW gearbox for a leading Cement company from India High Power Hydel -vertical
axis -2.5 MW
 2000
Oracle based ERP Pro-E platform for entire business
 1999
First high power gearbox 10 MW for a leading sugar company in South India Commissioning of
Test rig for testing upto 35 MW Gearbox
 1998
CFT Training on High power High speed technology at Lufkin – US ISO 14001 Certified
 1997
Business Process Reengineering initiated through a world leading consulting company
 1996
Replacement for IH I Compressor Gear sets - 32000 RPM and 28000 RPM for India's leading
petrochemical company
First High Power API-613 for Refinery blower application
 1993
First High Speed 6 MW API - 613 Gearbox for a Refinery in South India. ISO-9001 Certified -
First in Gear industry
 1992
First Gearbox for High Speed Test Rig for defense segment
 1990
Precision grinding facility extended with addition of Hoffler Grinding Machines.
 1987
First Supply of indigenized Traction gears for Rajdhani Express (Indian Railways)
 1982
First Hydel gearbox shipped to site
 1981
First retrofit supply to shipping industry for crude oil pump turbine gear set
1980
First gearbox supplied to a non-captive steam turbine OEM
 1976
Unit started at Mysore, to cater to captive consumption
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4.0 QUALITY & CERTIFICATIONS

Every Triveni product passes through the stringent quality checks from raw material to final run
test, assembly and packing to ensure that product meets or exceeds customer expectations.
We have an in house metallurgical laboratory with state-of-the-art equipment to inspect the raw
material properties, grain size, inclusions, banding and micro structure. This also ensures complete
quality requirements of the case hardened Gear teeth as regards to the hardness gradient, case and
core hardness and microstructure.
Core raw material chemical composition and carbon percentage in heat treated teeth are tightly
controlled through sophisticated optical spectrometer. The installation of magnetic particle testing
and surface etch inspection also ensures defect free gear teeth that last long.
All these equipment and quality infrastructure undergo predetermined calibration regime. These
also include heat treatment furnace and quenching stations to consistently produce high quality
gear.
Triveni's mechanical run test stand consist of three fully instrumented test benches of 1600 KW,
600 KW & 200 KW capacities with capabilities of tandem testing. Process capability is established
across processes in the complete value chain from raw materials to finish product. Test beds are
equipped with
 Bently Nevada vibration monitoring system with ADRE

 Vibration analyzer SKF Micro log
 Noise analyzer.
CERTIFICATION
 ISO-9001 : 2008 for QMS
 ISO-14001:2007 for EMS
 OHSAS-18001
 CE certified for self-certification of Gearbox and accessories
 CII-Exim Bank award for Business Excellence for "Strong commitment to Excel".
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CE
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ISO 14001 : 2004
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ISO:9001:2008
OHSAS
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AGMA MEMBER
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5.0 OUR PRODUCTS

5.1. SALIENT FEATURES
Fig 1 Gear box

We follow international standards for manufacture of Gearboxes. Engineered to order gearboxes
are supplied with Gear internals having single or double helical tooth profile.
All critical operations for the rotating elements from Gear hobbing, heat treatment, surface
grinding -and teeth grinding are all carried out in-house.
Gears are made of alloy steel forgings sourced from approved vendors as per stringent standards.
Gear sets are housed in robust but value engineered cast iron/ fabricated housing. Accessories to
Gearboxes like shaft driven oil pump/ lube oil system / barring gear system are sourced from
approved supplier partners.
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5.2. TYPES OF GEARS AND GEARBOXES
Fig 2 Fig 3
Helical and double helical gear drives Single stage and multi stage gear drives
Fig 4
Planetary gear drive
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6.0. APPLICATIONS Table 1
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Table 2
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Table 3
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7.0 Key strengths

• Technological advantage by virtue of License agreement with Lufkin Inc., USA (Now a
part of GE –Oil & Gas ), world renowned gear company
• Engineered-to-order gearbox solutions upto 62 MW under technology license from Lufkin
• Proven track record of supplying high speed high power gearboxes coupled with Niche low
speed gearboxes for the past 38 years cumulating to 8000 Gearboxes
• One of the few gear companies in the world having a turbine back up
• Brand acceptability across global OEMs – operating in India and Asia
• Design capability to address 62 MW power, 70,000 rpm speed
• Gear are designed to meet all global standards like AGMA, API, ISO, DIN and the only
company in India approved for API standard gearboxes as per latest edition
• Vast clientele across industry segments and application spectrum
• Vast application knowledge from the system perspective
• Experienced and skilled Manpower
• Integrated manufacturing facility capable of testing 90 MW Gearbox, handling 70 tonnes

and producing 2 mtr diameter gears
• Trouble shooting and diagnostics expertise
• Experience of reverse Engineering of 80+ global makes of gearboxes through replacement,

repair and refurbishing route for more than 25 years
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8.0 Technology
• Adopting to Global Standards like AGMA, API and DIN
• Case Carburized, Hardened and Ground Gears upto 2 Meter diameter
• Double Helical and Single Helical gearings both Internal and External
• High Efficiency using Double Helical Gearing for high power
• Pressure Dam bearing for low vibration under low load conditions
• Robust Casing design offering both Dry sump and Wet sump designs
• Proven designs across small to very high power range, across applications and speeds as
high as 70000 rpm
• Unique Hybrid design for Vertical Offset hydro turbine Gears
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9.0 Our clients
• OEM’s: Steam Turbine, Gas Turbine, Hydro Turbines Pumps, Compressors, FD and ID
Fans, Marine Propulsions, Test Rigs.
• Direct Users (for replacement solutions), Refineries, Cement plants, Steel Plants, Paper
plants, Petrochemical, Fertilizers plants, Rubber and Plastics processing and other process
companies in India and nearby countries.
10.0 Industries served

Wide variety of gearboxes are required for varied industry segments such as Power, Sugar,
Refinery, Fertilizer, Steel, Cement, Rubber, Plastics etc, Industry Segments
10.1 Power Generation
Geared drives
• Steam Turbine Generator
• Hydel Turbine Generator
• Geo-thermal (Steam Turbine Generator)
• Bio-mass (Steam Turbine Generator )
• Palm Oil ( Steam Turbine Generator )
• Gas Turbine and Accessory Gearbox
Non Geared drives
• Boiler feed pump
• Coal Mill drives
• Coal Pulverizer
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10.2 Fertilizer industries
• Carbomate Pump
• Ammonia Pump
• Boiler Feed Water Pump
• Compressor
• Granulator
• Dryer
• Wagon Tippler
• Blower
• Agitator
• Gas Turbine and Accessory Gearbox
10.3 Sugar industries
• Primary & Secondary Gearbox for mill and Fibrizor Drive
• Cane chopper / Shredder Gearbox
• Planetary mill drive gearboxes
10.4 Steel and cement industries
• Mill Stands ( Pinion stand / combined pinion stand for cold roll mill, Hot Strip Mill ).
• Briquetting Press / Share Press
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11 INTRODUCTION
Gears are toothed members which transmit power / motion between two shafts by meshing
without any slips. In any pair of gears, the smaller one is called pinion and the larger one is called
gear immaterial of which is driving the other. When pinion is the driver, it results in step down
drive in which the output speed decreases and the torque increases. On the other hand, when the
gear is the driver, it results in step up drive in which the output speed increases and the torque
decreases.
(Fig 5) Types of gears
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11.1 GEAR NOMENCLATURE
(Fig. 6) Gear tooth Terminology
Addendum: The addendum is the height by which a tooth of a gear projects beyond (outside
for external, or inside for internal) the standard pitch circle or pitch line; also, the radial distance
between the pitch diameter and the outside diameter.
Pitch circle: A pitch circle (operating) is the curve of intersection of a pitch surface of revolution
and a plane of rotation. It is the imaginary circle that rolls without slipping with a pitch circle of a
mating gear.
Module: Module, m this indicates the tooth size and is the number of mm of pitch circle
diameter(p.c.d.) per tooth
Pressure angle: Pressure angle in relation to gear teeth, also known as the angle of obliquity, is
the angle between the tooth face and the gear wheel tangent.
Dedendum: Definition of dedendum plural: The root of a gear tooth also the distance between
the dedendum circle and pitch circle of a gear wheel or rack
Root circle diameter: Root Diameter (R.D.) is the diameter of a circle around the bottom
(root) of the gear tooth space.
Base circle: The circle of an involute gear wheel from which the involute forming the outline of
the tooth face is generated.
Back lash: Backlash is defined as the amount by which width of tooth space exceeds the tooth
thickness of engaged gear when measured on pitch circle.
Face width:The face width of a gear is the length of teeth in an axial plane. For double helical, it
does not include the gap.
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PROCESS PLAN FOR HIGH SPEED GEAR TM3G3489
Table 4
PROCESS NO PROCESS CONTROL PARAMETERS STD HOURS
1 RAW MATERIAL INSPECTION(QA) As per Drawing 00
2 TURNING AND FACING As per Drawing 03
3 DRILL AND TAP As per Drawing 0.75
4 HOBBING(QA INSPECTION) No of teeth 159 Module 4.233mm 3.5
5 CARBURIZING(QA INSPECTION) Case depth 1.5 to 2.1mm 24
6 MACHINING AFTER CARBURIZING As per Drawing 2.5
7 HARDENING(QA INSPECTION) 60 to 63 HRC 10
8 TEMPERING 150 T0 180 deg 8
9 SHOT BLASTING By steel shots/grits 2
10 MACHINING AFTER HARDENING As per Drawing 3.5
11 DRILL AND TAP As per Drawing 2.5
12 BORE AND Ist FACE GRINDING As per Drawing 3
13 TEETH GRNDING(QA) No of teeth 159 Module 4.233mm 3.75
14 OD AND 2nd FACE GRINDING Allow it to dry 2.5
15 DEBUR AND DP TEST(QA) As per data sheet 00
16 BALANCING PREPARATION As per data sheet 4.0
17 DYNAMIC BALANCING(QA INSPECTION) As per std 4.0
18 DIMENTION INSPECTION As per drawing 00
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13 GEAR MANUFACTURING
PROCESS INVOLVED
1. BLANKING
2. DRILL AND TAP
3. HOBBING
4. CARBURISING
5. MACHINING AFTER CARBURISING
6. DRILL AND TAP
7. HARDENING
8. TEMPERING AND COOLING
9. SHOT BLASTING
10. MACHINING AFTER HARDENING
11. DRILL AND TAP BETWEEN RIM AND HUB
12. BORE,FACE AND OD GRINDING
13. KEYWAY MACHINING
14. SHRINK FITTING
15. TEETH PROFILE GRINDING
16. DEBUR AND DP TEST
17. DYNAMIC BALANCING
18. FINAL DIMENDION
19. ASSEMBLY
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13.1 GEAR BLANK MACHINING
Quality of gear manufacturing starts with blank machining. Accuracy in blank machining is a
necessity for attaining the desired quality standard of finished gears. According to shape, the gears
are called round gears and shaft gears.
For round gears, the dimensional and/or inter-related tolerances that must be closely controlled are
as follows:
 Size of the bore (inside diameter).

 Out of roundness or straightness of bore.
 Squareness of the bore axis with respect to face.
 Parallelism of the two faces.
 Outside diameter and runout with respect to bore.
Different defects in blank machining and their effects in subsequent gear manufacturing are:
1. Oversize bore results in poor clamping efficiency of the gear. Even a slight tendency to
slip on the work holding arbour may cause lead error. Geometrical error of the bore also
results in poor work holding efficiency.
2. Error in perpendicularity of the bore axis with respect to the locating face, results in
lead error and variation in lead.
3. Excessive parallelity error of work clamping face with respect to work locating
surfaces, results in non-uniform clamping and may twist the blank. In stack hobbing
(when numbers of blanks are placed one over the other and are cut simultaneously), it
causes lead error.
4. Excessive eccentricity of the outside diameter with respect to bore results in uneven
cutting load and causes varying tooth depth around the periphery.
Round gear blanks are machined generally in two setups on many types of chucking lathes. Three-
operation blank finishing ensures clean outside diameter. Two-operation finishing leaves a step on
outside diameter. However, with accuracy of present work holding chucks, the amount is well
within a limit that does not cause any trouble for ultimate performance. For shaft gears, the axis of
rotation is created by a face milling and centring operations on both the ends. The accuracy of the
operation is
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important to maintain accuracy in the subsequent operations. Generally a protected type centre
drill is used to avoid damage to the actual locating surface of the centre during handling. Shaft
gears blank machining requires careful planning to achieve the concentricity between different
locating surfaces and gear diameters. The tailstock pressure and the cutting forces may bend the
shaft depending upon the length/diameter ratio that may necessitate a judicious application of well-
designed steady rest.
13.2 HOBBING
Gear hobbing is a generating process. The term generating refers to the fact that the gear
tooth form cut is not the conjugate form of the cutting tool, the hob. During hobbing both the hob
and the workpiece rotate ill a continuous rotational relationship. During this rotation, the hob is
typically fed axially with all the teeth being gradually formed as the tool traverses the work face.
For a spur gear being cut with a single start hob, the workpiece will advance one tooth for
each revolution of the cutter. While bobbing a twenty-tooth gear the hob will rotate twenty times,
while the workpiece will rotate once. The profile is formed by the equally spaced cutting edges
around the hob, each taking successive cuts on the workpiece, with the workpiece, in a slightly
different position for each cut. Several cutting edge of the tool will be cutting at the also time. The
hob is basically a worm with gashes cut axially across it to produce these cutting edges. Each
cutting tooth is also relieved radially to provide chip clearance behind the cutting edge. This also
allows the hob face to be sharpened and still maintain the original tooth shape. The final profile of
the tooth created by a number of flats blending together. The number of flats corresponds to the
number of cutting gashes which pass the workpiece tooth during a single rotation. Thus, the greater
the number of gashes in the hob, the greater the number of flats along the profile which improves
the "smoothness" of the tooth profile.
(Fig. 7. Gear Hobbing process)
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13.3 THE GEAR HOBBING MACHINE:
A gear hobbing machine consists of five common elements:
 A work spindle to rotate the work.

 A hob spindle to rotate the hob.
 A means of rotating the work spindle and hob spindle with a constant of ratio, depending
on the number of teeth in the workpiece and the number of threads ill the hob.
 A means of traversing the cutting too across the face of the work in the direction of the
work axis for spur and helical gears.
 A means of adjusting the centre distance of the work and the hobs for different size
workpieces.
13.4 THE HOB:
As more and more threads are designed into the tool, the lead of the thread will
increase. Normally. A thread lead angle of 2-6° will be acceptable. Beyond six degrees, the left
and right side of the cutting tooth will be loaded unequally, which will cause poor tool life. To
compensate for this problem, the diameter of the tool can be increased slightly but with a reduction
in RPM to maintain the same SFM. Alternatively, the gash of the hob can be made helical to
position the cutting tooth perpendicular to the cutting action.
In Triveni gears we found that there are two Hobbing machines. The Gear wheels of
OD 75 mm to 2000 mm can be machined here from different hobs having module from 2 to 35. If
pinions are machined, they are held between the centres and if gear wheels are machined they are
supported on fixtures. The Job is usually made of 17CrMnNi6 material and the hob is made of
ASP2030 material. The helix angle of up to 45° can be cut. The hobbing also depend on Span,
Apex and MR. If we draw an imaginary tangent to the pitch circle, then the length of the tooth
which come under this tangent is known as span. The measurement is done between two rollers
keeping each side on the gear profile which gives Measurement over roller. The coolant used is
Garia20.
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Fig 8 Gear part and hob
The Typical Machine setting data for the Hobbing Process is as given below:
Table 5
01 No. of Teeth 159
02 Module 4.2333
03 Direction of Helix Left Helix
04 Standard Helix Angle 8° 17’ 37.30”
05 Pressure Angle 20°
06 Face Width 160.3 mm
07 Tip Circle Diameter 688.1.21 mm
08 Tooth Depth 10.61/10.74
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13.5 HEAT TREATMENT PROCESS
The heat treatment process is one of the most important processes that happen in order to improve
the various properties of the material of the metal. It is a crucial process because in the absence of
this process the manufactured gear will not be able to bear the extreme loads in the working
environment. The heat treatment unit at Triveni Gears in Mysore has a list of processes which
include carburizing, quenching, tempering and shot blasting.
WASHING
CARBURIZING
QUENCHING
TEMPERING
SHOT BLASTING
Sequence of operations followed for heat treatment.
The facility at ‘Triveni Gears Private Limited’ has a washing machine in order to clean the hobbed
gear component of external impurities. There are two carburizing furnaces where the component
can be subjected to high temperatures and subjected to the carburizing cycle. The quenching
chamber is essentially a hardening process where the change in the micro structure properties of
the metal takes place. The tempering process is followed after the quenching process in order to
relieve internal stresses and decrease the brittleness of the material. The final process is the shot
blasting process where the scales formed due to annealing are removed.
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13.5. 1 CARBURIZING PROCESS
Carburization is a heat treatment process in which iron or steel absorbs carbon liberated when the
metal is heated in the presence of a carbon bearing material, such as charcoal or carbon monoxide,
with the intent of making the metal harder. Depending on the amount of time and temperature, the
affected area can vary in carbon content. Longer carburizing times and higher temperatures
typically increase the depth of carbon diffusion. This process follows the process of washing where
the external impurities are removed. The carburizing processes followed for the hobbed gear wheel
and hobbed pinion is slightly different.
TEST PIECE
FROM QA
HOBBED GEAR HOBBED

WHEEL PINION
CHECK FORCASE
DEPTH, HARDNESSS APPLYING ANTI
CARBURIZING PASTE
CARBURISING
HARDENING
MACHINING AFTER
CARBUSRIZING
Fig 9 Carburizing process
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13.5 .2 CARBURIZING PROCESS SEQUENCE
The carburizing process employed at the plant involves the use of two organic fluids which are
acetone and methanol after the component is subjected to a particular temperature. The first liquid
introduced in the furnace has a function of scavenging the furnace and also providing the desired
positive pressure during the carburizing furnace. The liquids are supplied in drops at a particular
rate. The second liquid cracks to form the desired carbon potential. The advantage of this process
is that the carbon potential can be controlled and the need for an endothermic gas generator is
eliminated. In this plant methanol is used as the carrier gas and acetone as the carburising agent.
During carburizing methanol splits into carbon monoxide and hydrogen while acetone would give
carbon along with the above products.
CH3OH CO + 2H2
CH3COCH3 2C + CO + 3H2
The whole process is carried out in two cycles called the active and the deficient cycle. When the
carbon concentration of 1% is reached, it is termed the active cycle. When the carbon
concentration of 0.7 % is reached, it is termed as the deficient cycle.
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13.5 . 3 QUENCHING
Quenching is the process of rapidly cooling a material from high temperature to obtain certain
material properties. The thickness of the material to be quenched along with the rate of cooling
required helps to choose the quenching medium. The quenching medium of oil is chosen. If a
quenching medium that cools slower than the required rate is chosen, the quench is not effective in
producing the required microstructures and hence properties. On the other hand, if a quenching
medium that cools faster than the required rate is used, then that can sometimes lead to defects
such as warping and cracking. It prevents low-temperature processes, such as phase
transformations, from occurring by only providing a narrow window of time in which the reaction
is both thermodynamically favorable and kinetically accessible. Quenching process introduces
hardness in the steel by transforming it into martensite.
Fig 10 Time Temperature Transformation curve for steel
During the quenching process the metal is dipped in heated oil at a temperature of about
800 degree Celsius and cooled suddenly in a cooling pit in a very small time frame. The cooling
agent used is solid carbon dioxide which can maintain a temperature of -80 degree Celsius. At this
very low temperature the crystalline structure of steel changes from austenite to martensite which
is a very hard structure of steel. So this is also termed as the hardening process. Low viscosity
accelerated quenching oils are used mainly in hardening plain carbon and alloyed quenching and
tempering steels. Good penetration and / or through-hardening can be achieved.
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13.5.6 TEMPERING
Tempering process follows the quenching process because of the drawbacks associated with
quenching. Although quenching introduces hardness in the material, it also has the following
drawbacks:
 Martensite obtained after hardening is extremely brittle and will result in failure of
engineering components by cracking.
 Formation of martensite from austenite by quenching produces high internal stresses in the
hardened steel.
 Structures obtained after hardening consists of martensite and retained austenite. Both these
phases are metastable and will change to stable phases with time which subsequently
results in change in dimensions and properties of the steel in service.
In the plant tempering process is carried out by heating the quenched component to a temperature
of about 160 degree Celsius for a specified time frame.
Fig 11 Temperature v/s Hardness curve
It is observed that the increase in the tempering temperature decreases the hardness and internal
stresses while increases the toughness. Therefore a tempering process is a payoff between
achieving good toughness and losing the hardness. Depending on the application of the end
product the hardness of the component is maintained.
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13.5.7 SHOT BLASTING PROCESS
Shot blasting is a method used to clean, strengthen (peen) or polish metal.
After the process of quenching, scale formation occurs on the surface of the metal. These scales
remain even after the tempering process which is primarily to increase the toughness. Therefore
shot blasting is a necessary finishing process.
Aluminium oxide is blasted on to the steel. Aluminium oxide (AL2O3) is a man-made fused
alumina that is very tough, angular shaped, medium density with hardness of 9 on the Mohs scale.
This is abrasive is designed for designed for high blasting pressure up to 90 PSI. Aluminium oxide
is very good for light deburring and surface prep (bonding strength) prior to painting and
coating.AO creates a dull matte finish. Aluminium oxide has media life of approximately 10-12
times through the blast system.
Shot blasting is used in almost every industry that uses metal, including aerospace, automotive,
construction, foundry, shipbuilding, rail, and many others. There are two technologies used: wheel
blasting or air blasting.
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13.6 Effect of Heat treatment
Gear size and accuracy Heat treatment processes produce changes in tooth geometry. The gear
profile exhibits a drop after heat treatment depending on the module. Helix angle of gears becomes
decreased, as the helical tooth tends to straighten. The gear with higher helix angle will have more
increase in lead. There is certain growth or shrinkage on the pitch circle diameter (measured over
pins or balls) of the gears. Pitch circle diameter of inside splines shrinks and exhibits out-of-
roundness error. The pitch circle diameter increases in case of solid external gears.
Some important factors responsible for these changes are as follows:
 Hardenability of gear material. Z

 Forging practices.
 Cutting tools used in machining e.g. shaving cutter, broach etc.
 Work support and pattern of loading in carburising.
 Work location on a tray.
 Temperature and its uniformity and control of carbon potential and uniformity of carbon
absorption and diffusion.
 Difference in cooling speed, cooling agent and necessarily design of hardening and
quenching units.
Main objective of the development work in heat treatment process aims to

achieve a predictable and controlled distortion and dimensional changes. With established
heat treatment changes, it is possible to provide allowances at soft finishing stages to
achieve the final dimensional tolerances for transmission gears. Over pin size of
transmission gears after shaving is kept less to take care of growth. Helix angle during
shaving is kept less to achieve helix desired after heat treatment.
Page 36
13.7 Profile Grinding
Grinding in one form or another has been used for more than 50 years to correct distortions in
gears caused by the high temperatures and quenching technique associated with hardening.
Grinding improves the lead, involute and spacing characteristics. This makes the gear capable of
carrying the high loads and running at the high pitch line velocities required by today's most
demanding applications. Gears that must meet or exceed the accuracy requirements specified by
AGMA Quality 10-11 or DIN Class 6-7 must be ground or hard finished after heat treatment.
Different Gear Grinding techniques are as follows:
Gear grinding with the continuous generative grinding technique using grinding worms from
Wendt and Winterthur
In this technique, the tool corresponds to a grinding worm, the basic tooth profile of which should
always be seen as a rack profile. The involute form is generated through continuous generative
grinding of the grinding worm and the gearing. The process lends itself very well to the series
production of gear wheels; here, conventional or electroplate-bonded CBN grinding wheels are
used. The advantages of this technique are:
 High concentricity accuracy and pitch accuracy
 Constant involute form and flank line around the full circumference of the gearing
 Short machining cycles
Gear grinding with globoidal grinding worms (continuous profile grinding)

unlike the continuous generative grinding technique, the grinding tool in this case does not
correspond to a grinding worm with a rack profile as the basic tooth profile. Instead, a globoidal
grinding worm maps the contour of the tooth flank. During the grinding process the tooth form is
produced through virtually linear engagement of the tool in the tooth gap. This method is
predestined for grinding bevel gears which are used primarily in differential gears. A distinction
needs to be made between bevel gears without an offset (spiral bevel gears) and bevel gears with
an offset (hypoidal bevel gears).
Page 37
Fig 12 Single flank generating grinding
The involute shape is produced in a generative grinding process in which the grinding wheel only
machines a single flank in the direction of grinding per tooth gap. This method allows the
machining of different moduli with an unchanged wheel width and allows different infeed for the
left or right-hand tooth flank. In recent years, this technique has been increasingly displaced by
CNC-controlled form or profile grinding.
From profile grinding with radial infeed
With the aid of CNC dressing, the involute form is transferred to the grinding wheel, which then
generates the form in the tooth gap of the workpiece. However, the process of the vertical infeed
into the tooth gap has the disadvantage that very large contact areas are generated which extend
beyond two tooth flanks and that, as a result, the risk of grinding abuse is significantly increased.
Form or profile grinding with rotative infeed :

In the same way as described above, here again CNC dressing is used to transfer the involute form
to the grinding wheel, which then generates the form in the tooth gap of the workpiece in
accordance with its programming. This method has the advantage that the grinding allowance is
distributed more evenly between the head and base of the tooth, and that only one flank is
machined per pass, which allows the contact area to be reduced.
Page 38
Winterthur gear grinding expertise

The key variable for increased efficiency in the grinding process, the related rate of material
removal MRR, normally follows the following simple relationship during creep-feed grinding or
surface grinding:
MRR = radial depth of cut ae x feed rate vw/60.
For gear grinding this obviously does not apply strictly as above. As the involute describes a curve,
the equation cannot reflect the effective values at the individual points of contact of the involute.
The effective infeed qn must therefore change over the complete involute length and only
corresponds to the infeed ae at the base of the tooth (refer to the illustration, "Graf" p. 84).
Consequently, we have developed a program which looks at five data points over the involute and
thus guarantees perfect grinding results (refer to the illustration, "Graf" p. 85).
 Tooth size
 Angle of pressure
 Angle of inclination
 Radial infeed
 Feed value
Increasing importance of CBN for gear grinding:

As the second-hardest material after diamonds, this material has now largely established itself as
the standard grinding material in the automotive industry for components like crankshafts and
camshafts. The situation is different in the gear wheel industry, where, due to the high costs of
CBN grinding tools, the preferred approach is still to grind gear wheels made of tempered and/or
hardened carbon steels predominantly with fused aluminium oxide. This makes good sense, but
only in applications with low production volumes and/or applications involving the machining of
steels which are not tempered or are not high-tempered. For example, pump wheels for the textile
industry which are made of high-alloyed tool steels simply can no longer be manufactured cost-
effectively using conventional grinding materials. The solution:
Page 39
Electroplate-bonded CBN grinding worms and wheels from Wendt

Used for example for combined CBN generative grinding and profile grinding systems for gear
wheels or for tooth flank grinding on gearbox gear wheels. The advantages include:
 Single-layer grinding covering with high-strength bond
 High dimensional accuracy and profile accuracy possible
 Extremely high grinding performance
 Good bite thanks to large grain protrusion
 Cores can be recoated repeatedly
13.8 QUALITY MEASUREMENTS IN GEAR MANUFACTURING
During gear cutting and finishing, some errors of the gear teeth are closely monitored to
achieve the desired quality standard of the finished gears.
1. Tooth thickness error: It is the difference of tooth thickness between all the teeth at pitch
circle diameter.
2. a) Individual pitch error: It is the difference between the actual pitch on its pitch circle
to an adjacent tooth and the correct value.
b) Adjacent Pitch error: It is the difference between the two adjacent pitch as on the pitch
circle.
c) Accumulated pitch error:It is the difference between the sum of actual pitches between
any two teeth on the pitch circle and the correct value.
3. Total profile error:It is the sum of errors both in positive and in negative sides within the
region of tooth profile measurement measured vertically to a correct involute as a basis,
which passes through the intersection of an actual tooth profile and the pitch circle.
4. Total tooth lead error:It is the difference between a theoretical curve of tooth trace and
that of an actual tooth trace corresponding to the necessary region of tooth profile
measurement on the pitch cylinder.
5. Runout: It is the maximum variation of positions in radial direction of a contacting piece,
e.g. a ball or pin, which has been made to contact with both tooth surfaces of the space
close to the pitch circle.
Page 40
6. Backlash: It is the play on the reference pitch circle of a pair of gears engaging with each
other. The magnitude of backlash for the different gear accuracy grade is established by
standards.
7. Transmission error –Transmission error of a gear pair is the 'deviation of the position of
the driven gear, for a given angular position of the driving gear, from the position that the
driven gear would occupy if the gears were geometrically perfect
Each gear error causes certain performance deficiency of gear pair in mesh.
 Tooth thickness error - It causes excess or reduced backlash between the mating gears.
Reduced backlash causes binding. Excess backlash may cause noise (on reversal) and if
excessive, loss of tooth strength.
 Accumulated pitch error and runout result in gear noise and non-uniform motion
transmission.
 Profile error causes disruption in uniform conjugate tooth action and uneven loading. It
results in non-uniform motion transmission due to momentary disturbances of the
rotational velocity, and also causes noise.
 Lead error causes inadequate face width contact between the mating gears. It creates
again uneven loading, localised bearings and wear. It results in non-uniform motion
transmission and noise.
 Transmission error causes noise and vibration.
Page 41
Fig 13 Online measurement
Many standards, e.g. AGMA, DIN, JIS, BSI, cover gear error tolerances.
Quality assurance of gears requires various types of measuring equipment during the
manufacturing processes:
13.9 Elemental Checking:
Tooth thickness: Different instruments, such as tooth caliper, addendum comparator, measure the
tooth thickness depending on the tolerance limits. Vernier gear caliper, Fig. 4.84, measures the
chordal thickness at the nominal pitch circle.
Addendum Measurement: Addendum comparator, Fig 4.84, measures tooth thickness by

comparing the gear addendum with that of a basic rack. The comparator jaws have the same angle
of the tooth form of the gear to be checked. The comparator jaws are set to proper width with the
help of a master corresponding to a rack tooth of proper module. The indicator reads zero on this
master. Variation in the indicator reading (+or) implies the difference in the thickness of the gear
being measured with theoretical value. Corrections for taper and dimensional deviations of outside
diameter of the gear blank are made as the outside diameter is used as reference point.
Page 42
Span Measurement: A tooth Vernier caliper or plate micrometer measures the distance over two
or more teeth along a line tangent to the base cylinder, Fig. 4.85. The measurement directly relates
to the thickness of a single tooth (or the backlash contributed by the gear to the pair). Span
measurement process suits for spur and helical gears of even or odd number of teeth. It is possible
to measure the gears while on gear cutting machine (often while the machine is running). The
differences in measurements around the gear are readily noticeable indicating the need of repair of
the machine. A small 25 mm range micrometer can handle gears of quite large pitch circle
diameter. Dial calipers with at least one plane anvil are suitable for helical gear measurement,
while a cylinder-and-sphere anvil dial caliper is acceptable for spur gears only. For a narrow face
width gear with high helix angle, the process is not recommended as the spanning of a sufficient
number of teeth becomes difficult. For modified profile, the measurements will be erroneous.
Runout or size variation of outside diameter does not affect the measurement. However, base pitch
errors influence the readings.
Measurement over pins (balls): The over pin (or ball) size of the pitch circle diameter of a gear
controls the centre distance and backlash of the gear pair. Measurement is easily done for a spur
gear with help of a micrometer. The over pin size for helical gears having an even number of teeth
is measured by keeping two pins of specified size diametrically opposite in the tooth space, Fig.
4.86. For helical gears having odd number of teeth, the measurement is somewhat difficult. Little
improvement may be there in measuring over two properly placed balls. The diameter of the
measuring pins (balls) is such that it makes contact with the tooth flanks in the vicinity of pitch
circle where the involute error is minimum. Variation or runout of outside diameter does not
influence on the accuracy but errors in spacing and profile does affect the measurement. The
method is almost universally used to check and control the size of gears at all stages of gear
processing - cutting, soft finishing, hardening as well as hard finishing.
Profile: Measurement of an involute profile is based on its geometric property (A line normal to
an involute curve is a tangent to the base circle). An involute is thus the co-ordinates of heights to
a tooth and angles from the base circle, Fig. 4.87. A base circle disc and straight edge are used to
measure the involute profile. Gear is mounted with a base circle disc coaxially. A small pressure
applied between the straight edge and the disc moves them simultaneously.
Page 43
Pitch variation: Pitch variations are measured in two ways:
 Precision indexing: The gear is indexed accurately (mechanically, electronically or

optically). A single probe measures the actual position of each tooth relative to the
theoretically correct position of each tooth. Adjacent and accumulated pitch error is directly
measured
 Tooth space comparison: A two probe system records the distance from a point on tooth
number 1 to the corresponding point on the tooth number 2. The two probes continue
checking all around the gear one after another. The system only compares the tooth gaps.
Each measurement is taken from a different datum. For direct contact type measuring
probes, surface finish of tooth flanks affects the result. A proximity measuring probe
averages the flank irregularity.
Runout: A ball or roller of specified size placed in each tooth gap, Fig. 4.89 measures the radial
runout on the pitch circle diameter.. Presently, a single machine checks almost all the parameters
in same setup. The machines are conventional mechanical type or fully computerised numerically
controlled type with different level of automation.
Page 44
13.10 CNC Gear Measuring Centre:
CNC gear measuring centre checks all the important gear tooth errors and modifications
automatically with better accuracy and in very short time. It does not need any base circle disc.
The stylus moves in a tooth space, and the automatic measuring starts. Generally, right and left
flanks of 4 teeth at 90 degree apart are measured. A single probe performs all the measurements
with movements produced by individual table and slide on several axes, Fig. 4.91 through a CNC
continuous path control system. The CNC control determines the required relative feed rate for the
measuring links and the speed for the rotary workpiece drive to suit the individual tests based on
the gear data input. The control system calculates the theoretical base circle radius. The deviations
from the nominal involute form and the nominal helix are registered and transmitted to the
computer. For pitch measurement, the rotary and linear measuring systems register and transmit to
the computer the exact angular position of each tooth flank. The electronically controlled tracer
stylus advances into and withdraws from the tooth gaps on completion of the measured data
pickup, while the workpiece rotates continuously. The desired information about the errors appears
as traces and digital form on screen and may be plotted and printed automatically. Automation to
any desired extent is possible.
Fig 14 CNC Gear Measuring Centre
Page 45
14 Assembly and Testing
Casing Deburring, casing bore,

bedding with mandrel
Cleaning and Improve tooth face contact,

QA verification
flushing process Thermocouple and RTDs
Water jet cleaning and flushing
1 tonne and 10 tonne Dynamic balancing of gear set with

dynamic balancing shop coupling hubs/simulated shaft
machine coupling hubs
QA verification Gear assembly and parameter

checking and adjustment
1600kW , 600Kw, Prepare gear box on test bench carrying

200kW testing out oil flushing, MRT inspection and other
processes
QA
verification
Final assembly of gear box fixing

accessories, RTDs and nameplates
Release to dispatch
Fig 15 Assembly and Testing
Page 46
14.1. Dynamic Balancing
1. Causes:
The International Standards Organization defines unbalance as:
“That condition which exists in a rotor when vibratory force or motion is imparted to its
bearings as a result of centrifugal forces”.
The more popular definition is:
“The uneven distribution of mass about a rotor’s rotating centreline”.
The key phrase being “rotating centreline” as opposed to “geometric centreline”. The rotating
centreline being defined as the axis about which the rotor would rotate if not constrained by its
bearings. (Also called the Principle Inertia Axis or PIA). The geometric centreline being the
physical centreline of the rotor. When the two centrelines are coincident, then the rotor will be in a
state of balance. When they are apart, the rotor will be unbalanced.
Different types of unbalance can be defined by the relationship between the two centerlines. These
include:
Static Unbalance – where the PIA is displaced parallel to the geometric centerline.
Couple Unbalance – where the PIA intersects the geometric centerline at the center of gravity.
(CG)
Dynamic Unbalance – where the PIA and the geometric centerline do not coincide or touch.
2. Corrections:
When unbalance has been identified and quantified, the correction is straightforward. Weight has
to be either added or removed from the rotating element. The ultimate aim being to reduce the
uneven mass distribution so that the centrifugal forces and hence the vibrations induced in the
supporting structures are at an acceptable level.
Page 47
Field Balancing:
Many rotors can often be balanced in place, running at their own operating speed, with
minimum disassembly. To balance in place, of course, a basic requirement is that the rotor has to
be accessible to make corrections. Machines such as fans and blowers are good candidates. Totally
enclosed motor armatures and pump impellers are not.
The technique of balancing in place is referred to as Field Balancing and it offers some
distinct advantages including:
 Balancing is performed on the complete assembled machine and compensates for the
assembly tolerances discussed earlier.
 Costly and time-consuming disassembly to remove the rotor to a balancing machine is
eliminated.
 The effects of temperature, pressure, distortion and other environmental influences can be
incorporated.
 The resultant vibration can be the tolerance applied to the rotor, rather than the published
balance tolerances normally used in a balancing machine. This is particularly advantageous
if the supporting structure is close to a resonance. The unbalance in the rotor may have to
be adjusted to abnormally fine levels to minimize the resultant resonant structural
vibration.
Modern instruments such as vibration analyzers, data collectors and portable

balancers provide accurate information to assist in the balancing process. The vibration level
measured at the rotating speed frequency is used as an indicator of the amount of unbalance.
The location is determined by measuring the phase. Phase, (the relative motion of one part of a
machine to another) is measured by means of a stroboscopic light or by an indicator in the
instrument, triggered by a photocell.
It is imperative that the vibration measured is a result of the unbalance and not some
other exiting force. Only a detailed, thorough, analysis can identify where the vibration
measured is coming from. Many sources of vibration can occur at the rotating speed
frequency.
Page 48
When field balancing, trial weights for balance computation and permanent weights for
final correction are normally added to the rotor. Care should be taken when attaching weights.
They should be attached securely so that they cannot ‘fly off’ when the machine is operating.
They not only constitute a personnel safety hazard but also can cause damage. Loose balance
weights rattling around inside a turbine for example can wreck the machine.
Factory Balancing:
As part of the manufacturing process, most rotors are routinely balanced in a balancing
machine.
Fig 16: Balancing machine
Page 49
15. Conclusion
The past days of the internship have been a very instructive experience. During our time at
‘Triveni engineering and industries private limited’, we were offered a myriad of opportunities to
understand the functioning of the whole process unit. After having a look at the various processes,
we really obtained a connection with the theoretical and practical aspects involved. The various
intricacies with which the various production departments of the company coordinate came alive to
us. For instance, the heat treatment plant gave us a thorough understanding of the heat treatment
process and the time temperature transformation diagrams. Another unique opportunity which we
had was to gain insight into the working of high end CNC machines. On the whole it was an eye
opening experience in terms of the sheer exposure to the industrial processes we had.
Page 50

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Study of processes involved in manufacturing of high speed gear TM3G3489

1.0 COMPANY PROFILE

2.0 BUSSINESS OVERVIEW

Frame6 load gearbox order from USA

OHSAS 18001 certified

Went Live on SAP across all functions

Implemented 5S and Kaizen

Highest API-613 30 MW gearbox for the largest petroleum refinery

Highest 70,000 RPM gearbox for defense test rig

First order for SE Asian palm oil market in Indonesia Kaltimex

Balance score card PMS implemented

Setting up of full fledged in-house metallurgical testing facility

Development of first integrally geared 37935 rpm compressor indigenously

CNC hobbing and profile grinding technology adopted

Retro fit of vertical roller mill for Cement Segment

Plant layout optimization, technology and infrastructure up gradation

First High Power API-613 for Refinery blower application

4.0 QUALITY & CERTIFICATIONS

 Bently Nevada vibration monitoring system with ADRE

ISO 14001 : 2004

5.0 OUR PRODUCTS

Fig 1 Gear box

5.2. TYPES OF GEARS AND GEARBOXES

6.0. APPLICATIONS Table 1

7.0 Key strengths

• Engineered-to-order gearbox solutions upto 62 MW under technology license from Lufkin

• Brand acceptability across global OEMs – operating in India and Asia

• Design capability to address 62 MW power, 70,000 rpm speed

• Vast clientele across industry segments and application spectrum

• Vast application knowledge from the system perspective

• Experienced and skilled Manpower

• Integrated manufacturing facility capable of testing 90 MW Gearbox, handling 70 tonnes

• Trouble shooting and diagnostics expertise

• Experience of reverse Engineering of 80+ global makes of gearboxes through replacement,

• Case Carburized, Hardened and Ground Gears upto 2 Meter diameter

• High Efficiency using Double Helical Gearing for high power

• Unique Hybrid design for Vertical Offset hydro turbine Gears

9.0 Our clients

10.0 Industries served

10.1 Power Generation

• Steam Turbine Generator

• Hydel Turbine Generator

• Geo-thermal (Steam Turbine Generator)

• Bio-mass (Steam Turbine Generator )

• Palm Oil ( Steam Turbine Generator )

• Gas Turbine and Accessory Gearbox

Non Geared drives

• Boiler feed pump

• Coal Mill drives

10.2 Fertilizer industries

• Steam Turbine Generator

• Boiler Feed Water Pump

• Gas Turbine and Accessory Gearbox

10.3 Sugar industries

• Steam Turbine Generator

• Primary & Secondary Gearbox for mill and Fibrizor Drive

• Cane chopper / Shredder Gearbox

• Boiler Feed Water Pump

• Planetary mill drive gearboxes

10.4 Steel and cement industries

• Steam Turbine Generator

• Boiler Feed Water Pump

• Briquetting Press / Share Press