Shanthi Gears - Infrastructure

Total Area of the Land

5,661,051 sq. ft. (526,120 sq. mt.)

Total Area of the Building

945,098 sq. ft. (87,834 sq. mt.)

Total connected load

11,438 KW (approx.)

Diesel Generators

6,242.5 KVA

Own Wind Mills

6.66 Mega Watt

Number of Employees

903

Information Systems

IBM p550Q (2 Nos.) with IBM DS4700 Storage Server and IBM TS3100 Tape Library.

IBM p630 and IBM p615 Servers with IBM DS4300 Storage Server.

Intel Xeon Servers

Oracle ERP 11i Application Suite

Hummingbird Document Management System

Microsoft Exchange Server mailing system

Dedicated Leased Broadband internet access

Engineering

CAD SOFTWARE

Pro/ENGINEER Wildfire

SolidWorks Office Professional & SolidWorks Office Premium

Mechanical Desktop

AutoDesk Inventor

AutoCAD Mechanical

AutoCAD

CADian

VP Studio Mono

CAM SOFTWARE

Cimatron E

Keller

CAE SOFTWARE

Ansys

GEAR CALCULATION SOFTWARE

KISSsoft/Hirnware (AGMA, DIN & ISO)

Gear Rating Suite by AGMA

HARDWARE

DELL CX 300 Storage

DELL Power Edge 1800 Server

A0 HP Plotter

A0 Oce Copier

A0 Oce Plotter

A3 & A4 Copier, Scanner cum Printer

IN-HOUSE METROLOGY & CALIBRATION FACILITIES

We have the necessary calibration facilities with us, as such almost all the instruments are calibrated periodically in-house.

Universal Gauge Measurement System

LAB CONCEPT - 1000 (Make - TRIMOS - 0.3µm accuracy. Year 2005)

Can check & certify the following;
	Normal Plug and Ring Gauges
	Threaded Plug and Ring Gauges
	Internal & External Snap Gauges
	Calipers and Micrometers
	Depth & Length Measuring Gauges
	Dial, Test & Electronic Indicators
	Pin and Spacer Gauges
	Including Slip gauges & many more gauge types

Machine tool performance measurement and calibration systems with auto error compensation directly into the machine controller like Fanuc, Siemens, etc.

Co-ordinate Measuring Machine (CMM) calibration.

RENISHAW (Year 2003)

Laser ML 10 Gold

The ultimate metrology tool for traceable machine tool and motion system analysis for Linear, Angular, Rotary & Squareness measurements. Rotary measurement done with RX 10 rotary indexer.

Ballbar QC 10

Check machine positioning performance and diagnose machine errors automatically.

Auto Error Compensation

Measures the actual error, feed the data to the compatible machine tool control system (Fanuc, Siemens, etc.) so that it automatically compensates for the existing position error.

Flatness Measuring Equipment

Monochromatic Checklite - To check the parallelism and flatness of the measuring faces of the gauges. Accuracy less than one light band ie. 0.000295 mm.

Dial Gauge Calibrating Equipment

Mitutoyo UDT - 2 Dial Gauge Tester (Range 0 - 80 mm)

IN-HOUSE QUALITY ASSURANCE FACILITIES

Material Testing Facilities

Spectrometer (Year 2004)

Chemical Lab for Volumetric Analysis

Union Microscope (X 1000) with Camera attachment.

Image Analyser

Micro hardness tester - Zwick 3212B

Tooth flank hardness tester - EMCO N7F000

Fully automated micro vickers hardness tester - Zwick ZHV-1A

Equitip - Portable hardness tester

Die penetration testing

Crack detection with Ultrasonic testing.

Magnaflux - Magnetic particle crack detector.

Universal testing Machine - 20 Tons.

Izod testing facility

inverted metallurgical microscope with micrometer (Make : Nikon, Model : (Epihot 200 BD set 220/240V)

Co-ordinate Measuring Machines

3D Co-ordinate measuring machine (Make - Brown & Sharpe) with scanning facility. Total 2 Nos.

Global Image 3000 mm X 1200 mm X 1000 mm (Year 2003)

Global Status 1000 mm X 700 mm X 700 mm (Year 2003)

Leitz - PMM c-1000 (2.4M X 1.6M X 1M) with all types of gear measuring software (Year 2006)

Universal Measuring Machines

CARLZEISS

Leitz-Strasmann

SIP (Schuette) model MU-214B

Vertical Measuring Instruments

TRIMOS VT 600MA, Range 0-875 mm, Resolution 0.1µm

TRIMOS TVD 800A, Range 0-800 mm, Resolution 0.1µm

Mitutoyo LH 600B, Range 0-972 mm, Resolution 0.1µm

Surface Finish Tester

Surf test - SV 400 Portable (Make - Mitutoyo). Stroke 50 mm, Accuracy 0.1µm

Surfcom 480A - High precision surface finish analyser (Make - Tokyo Seimtsu)

Contour Tester

Contourecord 2600E - 24 - N (Make - Tokyo Seimtsu)

Profile Projector

Metz - 804 Magnification X 20, Screen Ø600 mm

Nikon V-20B Magnification 10x, 20x, 50x, Screen Ø500mm

Gear Testers

Total 13 Nos. (Make - Klingelnberg Hoefler P40 (Year 2001) WENZEL WGT350 (Year 2006), PFSU1200, PFSU640, PFSU62, PSR500, Hoefler EFR 401MZ, Maag SP60 and PH60, CarlMahr 891, 898D, Goulder Mikron CSF/2, 3R)

CNC Hypoid Tester

Gleason No.519 Angular Hypoid Hydraulic Tester (Year 2005)

Gear Noise Tester

Hurth ZP 320 - To test a gear with a master gear or a gear pair for any process error by measuring the noise produced during running at operational speed. Work piece max. Ø320, Speed max. 3000 rpm.

Hob Tester

KLINGELNBERG PWF - 250 upto 20 module

Worm Pair Tester

Adjustable center distance worm pair checking machine with DRO upto 17 inch CD (Make -

)

IN-HOUSE MANUFACTURING FACILITIES

Cast Iron Foundry and Pattern Shop

5,000 Tons p.a.

Medium Frequency Induction Furnaces

1,500 Kg., 500 Kg. - each 1 No.

Moulding Machines

	ARPA 300 & 450
	Unitherm 450
	ARPA 900 (Year 2004)

Fully Mechanised BMD Sand Plant 20 Tons/hr mixing

Single piece casting max. Wt. 2000 Kg.

Finishing shop with Hanger type shot blaster VP14 (Year 2005) and other facilities for 700 Tons/month.

6 Cu. Ft. Tumblast type shot blasting machine (Capacity : 350 Kg. Make : Nesco, Model : TBS-6) with automatic loader assembly and pulse jet type dust collector (Model : 1025 RA 108)

Full fledged Pattern shop with CNC vertical machining centre.

Wooden and Aluminium Patterns developed over the years exceeds 20,000 in numbers.

Non-Ferrous Castings

Centrifugal casting of Phosphor Bronze rings upto Ø1200 mm

Induction melting furnace 75 KW/3000 Hz VIP power TRAK-R-SI with 150 Kg duraline furnace (Make : Inductotherm)

Gravity die casting of Aluminium

Forgings

Open forgings of blanks upto 500 Kg. single piece

Heat Treatment

Gas carburising with pit type furnace 5 Nos. (Diameter/Depth in mm; 600/1000; 900/1300; 1000/1300; 1705/1600) (Make - Unitherm, Welmech, Westerwork - Degussa)

Gas carburising furnace (GCF-1) 133.5 KW (1800 x 2000) and 90 KW (900 x 1300) (GCF-3) with cooling pit (1800 x 2000) and 10,000 lit. capacity quenching tank. (Make : Welmech)

2 Nos. Electrically heated pit type hardening furnace - (PEGAT Ø 1000 X 3000 mm and Ø 2500 X 1500 mm) (Make - Eltherma)

2 Nos. Electrically heated endo - Gas generator ENE-20 with automatic system of dew point (Make - Eltherma)

Electrically heated Bogie Hearth furnace for stress relieving (Make : Unitherm, Model : UBA 200/200/400)

Electrically heated pit type vertical sealed retort furnace for gas nitriding and gas nitro-carburising (Make : Unitherm, Model : UVNRF NC 86/140)

Electrically heated pit type furnace for normalising (Make : Unitherm, Model : UVAF 120/220)

4 Nos. Tempering Furnaces (Make : Elterma, Capacity : Ø2500 x 1500 mm and Ø1000 x 3000 mm) 1 No. Tempering Furnace (Make : Welmech, Capacity : Ø900 x 1300 mm

Washer with spray washing Ø2500 x 1500 mm

1 No. Quenching tank Ø2500 x 3000 mm, Capacity : 70,000 lit. (Make : Elterma)

1 No. Quenching tank (Make : Unitherm, Model : UVOTQ 175/200-30, Capacity : 30,000 lit.)

2 Nos. Quenching Tanks 10,000 lit., 30,000 lit.

1 No. Shot blasting & shot peening machine with 72 inch rotary table & double door (Make - INDABRATOR)

Total gas carburising system is controlled by computer

Electrically operated salt baths (4 Nos.) for hardening HSS - M35, TST30 (ASP30) material used in our cutter manufacturing.

SECO/WARWICK 15.0 Vacuum Carburising Furnace with convection heating & 15 Bar Gas Quenching System.

Subzero treatment with COMETAIRE model machine size 600W X 450D X 450H - max. Wt. 75 Kg.

Fabrication

Steel fabrication upto 20 Tons, single piece

CNC Gas cutting machine (Make - Lakshmi Zinser - 6000 mm X 2000 mm)

Cutting Machines

2 Nos. Double column fully automatic band sawing machine with automatic chip conveyor (Make : Everising, Model : H-560HA & H-260B)

Circular sawing machine (Make : Everising, Model : P-100B)

Mig & Arc Welding Machines

Total 22 Nos. (Make - L & T Zuper arc - 400, Essab, Arcos, Advani - Oerlikon)

Facility to weld Cast-iron or Steel with Phosphor-bronze material with rotary table at controlled speed for worm wheel. 4 Nos.

Cutter Manufacturing

Gear Hobs and Milling Cutters upto 20 module

Universal CNC hob sharpening machine (Make : Essor, Model : LHG 3040)

Gear Grinders

Total 36 Nos.

1 No. Gleason PFAUTER CNC model P400G (Year 2006)

1 No. Gleason-PFAUTER CNC model P2400G with internal grinding attachment (Year 2005)

1 No. Gleason-PFAUTER CNC model P600/800G (Year 2005) with 3 internal grinding heads to grind internal gears with a minimum of 40 mm. PCD.

1 No. Höfler CNC model Mega 1600 (Year 2003)

23 Nos. (Make - Reishauers - RZ 820 (Year 2000), RZ 362A (Year 2003,2005), RZS (Year 2001), RZ 400 (1 No. Year 2006, 2 Nos. Year 2008) AZA, ZB, NZA and OZA)

6 Niles (Make - ZSTZ 12, ZSTZ 10, 630C3P, 630C2, etc.) and others

Höfler Profile form gear grinding machine (Model : Rapid 1250)

Höfler CNC gear grinding machine (Model : Helix 400)

CNC Gear Hobbing Machines

1 No. Gleason PFAUTER model P2000 - 2400 with internal Gear hobbing attachment (Year 2005)

1 No. Gleason PFAUTER model P800/1200 (Year 2006)

2 Nos. Cooper PE250 - 6 axis CNC (Year 2003 & 2006)

5 Nos. Cooper P254 - 3 axis CNC (Year 2004, 2005 & 2006)

7 Nos. HMT Heavy Duty model H400-4A - 4 axis CNC (Year 2005, & Year 2006)

1 No. Cooper P634 - 3 axis CNC (Year 2005)

1 No. CNC gear hobbing machine (Make : Liebherr, Model : LC 1200)

Gear Hobbing Machines

Total 66 Nos. (Make - Liebherr L 3200, L 1200, L 652, H 400, L200, Stankoimport 5A342 (2000), Pfauter P400, PA300, P251, RA200, P160, RA100, WMW - ZFWZ 1250/3, 800/3, 630/3, 400/3, 250/2, Hurth WF10, etc.)

High Precision Worm Wheel Hobbing Machine

Lorenz TM 3000 - Ø3000 mm X 10 module (For indexing drive worm wheels)

Gear Shavers

Total 4 Nos. (Make - Hurth ZSA 551 - 3 Nos. & 1 Russian)

CNC Gear Shapping Machines

1 No. Gleason PFAUTER PSA500 (Year 2006)

1 No. Gleason PFAUTER P800/1200ES with electronic guide (Year 2006)

Gear Shapers

Total 19 Nos. (max. Ø2400 mm) (Make - Reinecker, Maag, Liebherr, Henschel - Rober, TOS, WMW, Russian) & (Sykes - 5A for herring bone gears)

Tooth Rounding and Chamfering Machine

PICCO K15 Ø600 X 15 module (Year 2003)

CNC Hypoid Cutting Machine

Gleason USA, Phoneix 1000 HC CNC Hypoid Cutting (Year 2005)

CNC Hypoid Grinding Machine

Gleason USA, Phoneix 800G CNC Hypoid Grinder (Year 2005) with facility to grind Curvic coupling for indexing devices.

Straight Bevel Gear Machines

Total 4 Nos. - max. Ø1600 mm (Make - H & H, Klingelnberg, WMW)

Spiral Bevel Gear Machines includes Lapping, Sharpening & Testing

Total 23 Nos. - max. Ø850 mm (Make - Klingelnberg, WMW)

Tool Presetter

Zoller model smile 500 (Year 2005), max. length 500 mm, max. Ø400 mm

Zoller Venturion 600 (Year 2006) Length = 600 mm, Ø600 mm

Microset (Make - Gildemeister-Devlieg) (Horizontal) max. height 600 mm, max. Ø300 mm

TRIMOS TPR 300 max. height 300 mm, max. Ø250 mm

CNC Universal Machining Centre

1 No. 6 axis SHW, model UFZ 6L Travelling Column (12M) Machine for large components with rotary table (Make - FIBRO) Ø2.5M

Optical Profile Grinding Machine (OPGM) for cutting tools

1 No. (Make - WMW) model SWPO 80 CNC

2 Nos. (Make - WMW) model SWPO 80

Horizontal Machining Centres-CNC

2 Nos. MAZAK, JAPAN model FH 8800 (Year 2005 & 2006)

1 No. MAZAK, JAPAN model FH 10800 (Year 2006)

2 Nos. MAKINO, JAPAN model a51 (Year 2005 & 2006)

HMT 630

Table size - 630 mm X 630 mm 2 pallets Control System - Siemens 840D - 4 axis Automatic Tool Changer with 60 stations.

Vertical Machining Centres-CNC

2 Nos. Haas, USA Super - Speed VF-3SS (Year 2005 & 2006)

1 No. Haas, USA model VF5-40/XT (Year 2006)

Kirloskar VMC 40

Table size - 600 mm X 400 mm

Control System - Fanuc OM - 3 axis

Automatic Tool Changer with 24 stations

VMC

Table size - 740 mm X 400 mm

Control System - Siemens 810D - 3 axis

Zayer 3000 BF3

Table size - 3000 mm X 800 mm

Control System - Siemens 810D - 3 axis

CNC Horizontal Boring Machine

Juaristi TS1 (Year 2002)

Spindle - Ø125 mm

Control system HeidenHein 426 - 5 axis

Automatic Tool Changer with 60 stations

Heckert BFK - 150

Table 2000 mm X 1600 mm

Spindle Ø150 mm

Control system - Siemens 840D - 5 axis

WMW BFT 90 CNC

Table 1000 mm X 1000 mm

Spindle - Ø90 mm

Control system Siemens 840D - 4 axis

Maho MC 500

Table Ø500 mm

Control system Siemens 840D - 4 axis

Automatic Tool Changer with 24 stations

Horizontal Boring Machines - All with 3 axis DRO

Total 16 Nos. (max. - 5000 mm X 3000 mm) (Make - Skoda, WMW, HMT Pegard, Scharmann, Woton, VWF, Cooper, Russian, etc.)

CNC Jig Boring Machines

WMW model BK OZ 1400

Table size - 2200 mm X 1400 mm, 3 axis

Jig Boring Machines

Total 2 Nos. (Make - Hauser & Lindner)

CNC Thread/Worm Profile Grinding Machine with built-in tester

2 Nos. SAMPUTENSILI S375 G (Year 2003 & 2006) with provision for duplex worm grinding & Hob profile relief grinding attachment with software.

SAMPUTENSILI S 1000GW (Year 2006)

Thread/Worm Profile Grinding Machines

Total 8 Nos. (Make - Klingelnberg - HSS 350, Reishauer - UL 900, WMW GSU - 315 & GSU - 320 PC, Lindner - Ø400 mm X 3000 mm)

Thread/Worm Milling Machines

Total 11 Nos. - max. 3000 mm length, Ø250 mm, (Make - WMW, Wanderer etc.)

CNC Lathes

Turn mill centres

Gildemeister Linear CTX 620, with Siemens 840D system with Shopturn Software. (Year 2003)

Mill Turn 250Y Linear (Year 2004) with Siemens 840D system with Shopturn Software.

CNC Hard turning machine 2 Nos.

Hard Turn 210 (Year 2004) with Siemens 810D system. Machine with in-process controller (Make - Renishaw) Tool Probe 8 inch HPMA (High Precision Motorised Arm) & Job Probe LT 02 system consisting of LP 2 Probe and OMM (Optical Module Machine)

CNC High speed turning machine

Speed Turn 165 with Siemens 802D system. (Year 2004)

CNC Turning Centres

30 Nos. CNC Turning Centres (Make - Index, Gildemeister, G.D. Weiler, Jyoti, Niles, LMW, HMT, Protech, etc.)

2 Nos. DOOSAN - DAEWOO make CNC lathe with FANUC 0i T controller model : PUMA V550

DOOSAN - DAEWOO make CNC lathe with FANUC 0i T controller model : VT 900

3 Nos. DOOSAN - DAEWOO make CNC lathe with FANUC 18i T controller model : PUMA 240

Centre Lathes

Total over 20 Nos. - max. Ø1800 mm X 8000 mm (Make - Scharer, Voest - Alpine, Heyligenstaedt, Weipert, Ravensburg, Monforts, Weisser - Fronter, HMT, Kirloskar, etc.)

CNC Vertical Turning Centre

2 Nos. Cooper CVT 150 F (Year 2003 & 2006)

Control system Fanuc O - T.

Max. Ø1500 mm

Vertical Turret Lathes

Total 7 Nos. - max. Ø3300 mm & 3000 mm height. (Make - Froriep, Jungenthal, Dorries, Titan, Niles, etc.)

Plano Milling

Total 3 Nos. - max. 2000 mm X 8000 mm (Make - WMW & TOS)

Milling Machines

Total 31 Nos. (Make - Gambin, Klopp, Wanderer, Reckermann, Fritz Werner, Steinel, SHW, Maho, Deckel, WMW, etc.)

Broaching Machines

Total 6 Nos.- max. 40 Tons. (Make - Forst, Hofmann, Fromag)

Slotting Machines

Total 12 Nos. - max. 1070 mm stroke. (Make - Ravensburg, Waldrich Coburg, Russian)

Radial Drilling Machines

Total 16 Nos. - max. drilling Ø100 mm /2000 mm radius (Make - Batliboi, Raboma, Webo, Kolb, Donau, Csepel, Mas)

Roller Burnishing Machine

Hydraulic Centreless OD Burnishing machine (Make - Suriyaa) max. Ø66 mm

CNC Universal Grinding Machines with "MOVOMATIC" controller

2 Nos. Studer S33 CNC Universal Grinding (Year 2004 & 2006)

Kellenberger UR 175/1000 CNC Universal Grinding (Year 2003)

CNC Internal Grinding Machine

HMT model GC 225 CNC Internal Grinding (Year 2005)

2 Nos. Studer S151 CNC Internal & Face Grinding (Year 2006)

Internal Grinding Machines

Total 20 Nos. - max. Ø1000 mm bore (Make - Sielemann, Voumard, Overbeck, Reinecker, Fortuna, WMW, etc.)

Cylindrical Grinding Machines

Total 18 Nos. - max. Ø560 mm X 4000 mm (Make - HMT G22U, Schaudt, Studer, Fortuna, Overbeck, Cincinatti, TOS & Russian)

Surface Grinding Machines

Total 8 Nos. max. 2000 mm X 400 mm (Horizontal Spindle) and Ø1250 mm (Vertical Spindle) (Make - ELB, HMT, WMW, etc.)

Spline Grinding Machine

1 No. Max. Ø150 mm and 800 mm length (Make - WERNER Model - SKR 8A DIAG)

Dynamic Balancing Machines

Total 3 Nos.

Abro 1600 Kg. - 2 Nos.

Abro High Accuracy Dynamic Balancing Machine 5 Kg. Capacity for Balancing Aircraft Gears -1 No.

Number of Hobs
(Module, DP, CP, Sprocket, Splines, etc) with different pressure angles - 14.5, 15, 20, 25 and 30 etc.,

Over 12,000 Nos. of hobs (including Stub tooth cutters) along with necessary fixtures, mandrels, spacers & setting equipments in enormous quantities, accumulated during the last 36 years of our existence are available with us.

Almost all the requirements of gears, spur, helical, worm, worm wheel and bevel etc. having any module / DP / CP and with any pressure angle can be met, at short notice with jet speed.

We are capable and have the necessary wherewithal to supply soft gears within 24 hours incase of emergency/breakdown etc. and we have many such credentials to our credit.

Perhaps we are the only gear manufacturing company having all processes in-house including cutter manufacturing. No sub-contracting is done.