Manufacturing

We have ultra modern facilities necessary to design and develop a product to international standards. State-of-the art manufacturing facilities complement for complete manufacturing of gear products. With pool of qualified & skilled professionals having cumulative experience in respective field, we cater to our client’s specific requirements.

  • Total Area of land – Above 120 ACRES
  • Total Area of building – Above 1 Million Sq.Ft
  • Total Diesel Genset Capacity – 7422.5 KVA
  • Total Own Wind Mill Capacity – 6660 KVA

Manufacturing Facilities

Perhaps we are the only gear manufacturing company having all processes in-house including cutter manufacturing.

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.

Vacuum Carburising Furnace – SECO/WARWICK 15.0

Technical Specification
Uniform Zone size (WxHxL) 600x600x900 mm
Hearth Capacity 600 kg
Operating Temperature Range 150-1350°C
Convection Heating Range 150-850 °C
Temperature Uniformity +/- 5 °C
Furnace Size (WXHXl) 3.2 x 3.6 x 5.5 M

Cutter Manufacturing

  • Gear Hobs and Milling Cutters upto 20 module
  • Universal CNC hob sharpening machine (Make: Essor, Model: LHG 3040)

Hob Sharpening Machine – Luren LHG 3040

Technical Specification
Max Workpiece dia 250 mm
Min. Workpiece dia 20mm
Max Workpiece dia 300mm
Max.Module M10
Max. Gash Lead Angle +/-35°

Gear Grinders

    • Internal Helical Gears
    • DIN Q = 4 (Master gears also)
    • 1 No. Gleason PFAUTER CNC model P400G
Technical Specification
Max. workplace diameter 400 mm
Max. module can be ground 14 module
    • 1 No. Gleason-PFAUTER CNC model P2400G with internal grinding attachment (Year 2005)
Technical Specification P2400 G
Workable Diameter 2400 mm
Minimum/Maximum centre distance 300/1550
Maximum grinding depth/profile 80mm – with internal grinding and inspection
    • 1 No. Gleason-PFAUTER CNC model P600/800G with 3 internal grinding heads to grind internal gears with a minimum of 40 mm. PCD.
Technical Specification P600 / 800G
Maximum grindable work piece diameter 800 mm
Maximum grindable profile depth 35 mm – with internal grinding and inspection
    • CNC Gear Grinding Machine Höfler – Helix 400
Technical Specification Helix 400
Min./ Max. Gear Diameter Ø 10 mm – 400mm
Max. Module 0.5-15mm
Helix Angle ±45 °
    • 1 No. Höfler CNC model Mega 1600
Technical Specification MEGA 1600
Gear Diameter min 160
Gear Diameter max 1600
Grindable Module 1.5 – 30 mm
Pressure Angle 12 ° – 30 °
Helix Angle ±35 °
Grinding Wheel 400 – 300 mm
Profile Modifications max. 0.5 mm
Lead Modifications max 1.0 mm
    • CNC Internal Grinding Machine – Höfler Rapid 1250
Technical Specification Höfler Rapid 1250
Gear Diameter 1500mm
Helix Angle ±45 ° ; 90 °
Module 1-40mm
Table Load 6000 Kgs
Axial Stroke length Max. 1500mm
    • 23 Nos. (Make – Reishauers – RZ 820, RZ 362A, RZS RZ 400 (1 No., 2 Nos.) AZA, ZB, NZA and OZA)
Reishauer RZ 820The RZ 820 CNC continuous generating gear grinding machine is used for grinding large, heavy gears with high accuracy.
Technical Specification RZ 820
Outside diameter Max. 820 mm
Root diameter Min. 40 mm
Number of teeth 10 – 600
Module 1 – 8 mm
Helix angle ± 30°
Reishauer RZ 362 AThe RZ 362A high production CNC continuous generating gear grinding machine employs the continuous shift grinding method. External spur and helical gears are ground at the highest productivity and to the most demanding accuracies.

The grinding wheel is automatically dressed on the machine. An integrated fine balancing unit allows for the continuous balancing of the grinding wheel.

The RZ 362A is designed for automatic operation and can be used for single piece as well as short or long production runs, depending on the degree of automation.

Technical Specification RZ 362 A
Maximum tip Diameter 360 mm
Minimum root diameter 10 mm
Number of teeth 6 – 600
Module 1 – 8 mm
Helix angle ± 45°
Slide Travel (Z Axis) 175 mm
Weight 60 kg
Reishauer RZSThe CNC Gear Grinding Machine RZS is for, high quality, medium / high volume batch production

An integrated fine balancing unit on the RZS allows continuous balancing of the grinding wheel.

Technical Specification RZS
Maximum tip Diameter 360 mm
Minimum root diameter 10 mm
Number of teeth 6 – 600
Module 1 – 8 mm
Helix angle ± 45°
CNC Universal Grinding Machine – Reishauer RZ 400
Technical Specification
Maximum tip Diameter 400mm
Minimum root diameter
Number of teeth 5-999
Module 0.5-8mm
Helix angle ± 45°
  • 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

PGP hob- Proper jig& Fixture

    • 1 No. Gleason PFAUTER model P2000 – 2400 with internal Gear hobbing attachment
Technical Specification P2000 – 2400
Maximum Diameter 2400 mm
Table Diameter 1870 mm
Table Height 950 mm
Maximum Face Width 1000 mm
Maximum Table Load 30,000 kg
Nominal Module 20 mm
Hob Speed 20 – 200 rpm with internal hobbing
    • 1 No. Gleason PFAUTER model P800/1200
Technical Specification
Max. workplace Ø 1200 mm
Max. module can be hobbed 16 module
Max. axial slide travel 1000 mm
    • 2 Nos. Cooper PE250 – 6 axis CNC
Technical Specification PE250
Model PE-250
Max. Module 5 mm
Max. Diameter of Gear 250 mm
Max. Face Width 150 mm
Main Motor 11 kw
    • 5 Nos. Cooper P254 – 3 axis CNC
Technical Specification P – 254 P – 634
Max. Work Diameter 250 mm 630 mm
Max. Module 6 mm 10 mm
Max. Face Width upto helix angle 60º 245 mm 425 mm
    • 7 Nos. HMT Heavy Duty model H400-4A – 4 axis CNC Brand new latest CNC
Technical Specification H400 – 4A
Max. Work piece Diameter 400 mm
Max. Module 8mm
Max. Face Width 200 mm
    • 5 Nos. Cooper P254 – 3 axis CNC & 1 No. Cooper P634 – 3 axis CNC
Technical Specification P – 254 P – 634
Max. Work Diameter 250 mm 630 mm
Max. Module 6 mm 10 mm
Max. Face Width upto helix angle 60º 245 mm 425 mm
  • 1 No. CNC gear hobbing machine (Make : Liebherr, Model : LC 1200)

CNC Universal Hobbing Machines – Liebherr LC1200

Technical Specification
Max. Work Piece Diameter Ø 1200 mm
Min. Centre Distance 75 mm
Max. Centre Distance 800 mm
Max. Nominal Module for steel 12/60/20
Max. Hob slide travel 1000

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 & Bevel Gear Cutting

    • 1 No. Gleason PFAUTER PSA500
Technical Specification
Max. work piece Ø 500 mm
Max. module can be shaped 8 module
Max. face width of the gear 130 mm
    • 1 No. Gleason PFAUTER P800/1200ES with electronic guide
Technical Specification
Max. work piece Ø 1200 mm
Max. module 10 module
Max. face width of the gear 200 mm

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

Technical Specification K15
Max. Module 15 mm
Max. Diameter 600 mm
Spindle Speed 1450 – 2100 – 2800
Teeth production per minute 35 – 50 – 75

CNC Hypoid Cutting Machine :

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

PHONEIX 1000 HC
Technical Specification 1000 HC
Axis Travel (XYZ) 305 mm * 205 mm * 614 mm
Cutter diameter 176 mm, 210 mm, 250 mm, 300 mm, 350 mm, 350 mm
Fanuc b Axis system

CNC Hypoid Grinding Machine :

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

PHONEIX 800G
Technical Specification 800 G
Computer control with automatic setup and control of 6 Axes
X Axis 305 mm
Y Axis 305mm
Z Axis 686mm
Work piece capacity
Extreme ratio 10:1
Full depth (Maximum) 31.75mm
Face width (Maximum) 116.84mm

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, max. length 500 mm, max. Ø400 mm
Technical Specification
Maximum Length 500 mm
Maximum Diameter 400 mm
  • Zoller Venturion 600 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

Technical Specification SHW UFZ 6L
x-axis Column Longitudinal 12 M
y-axis Spindle Vertical 3.1 M
z-axis Headstock Transverse 1.6 M
Clamping Surface 3 M x 12 M
CNC System Heidenhain
Rotary tables Ø 2.5 M (Make : FIBRO)
Automatic Tool Changer
No. of Tools 90
Universal Head & Fork Head for 5 axis and added with Rotary table for 6 axis

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
Technical Specification FH 8800
Axis Travels (XYZ) 1300 mm * 1100 mm * 1000 mm
Pallet Dimension 800 * 800 mm
Tool Chain Magazine 80
High torque spindle 37 kw – 7000 rpm
Pallet Changer 2
    • 1 No. MAZAK, JAPAN model FH 10800
Technical Specification
Pallet size 1000 X 1000 mm
No. of tools on ATC 120 tools
    • 2 Nos. MAKINO, JAPAN model a51
Technical Specification a51
Axis Travels (XYZ) 560 * 560 * 500 mm
Automatic Tool Changing 60 tools1600
Maximum work piece size (Diameter * Height ) 630 * 900 mm
High speed spindle 22 kw ;50 – 1400 rpm
Pallet changes 1
  • 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)
Technical Specification VF-3SS
Axis Travels (XYZ) 1016 x 508 x 635 mm
High speed 24+1 side mount tool changer
High speed spindle 30 hp; 12000 rpm
Table size 1000 mm x 600 mm
    • 1 No. Haas, USA model VF5-40/XT
Technical Specification VF5-40/XT
Travels
X 1524 mm
Y 660 mm
Z 635 mm
Spindle Nose to Table 178 – 813 mm
  • Kirloskar VMC 40
  • Table size – 600 mm X 400 mm
  • Control System – Fanuc OM – 3 axis
  • Automatic Tool Changer with 24 stations
  • Shanthi 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 & Milling Centre Juaristi TS5

Technical Specification
Cross Travel (X) Juaristi 400mm
Vertical Travel (Y) 2500mm
Column Longitudinal TravelLongitudinal Travel (Z) 1775mm
Spindle Axial Travel 1000mm
Rotary Table Ø2000mm

CNC Milling Machine –BFW Surya VF30 CNC VS

Technical Specification
Table Size (Clamping area) 1060mm x 315mm
T-Slots No. / Width / Centre Distance 3 Nos./ 14mm / 100mm
Max. Load on Table 300 Kgs
Longtitudinal Movement (X) 800mm
Transverse Movement (Y) 350 mm
Vertical Movement ( Z ) 380 mm
Positioning Accuracy ±0.010mm
Repeatability ±0.005

CNC Horizontal Boring Machine

  • Juaristi TS1, 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 with provision for duplex worm grinding & Hob profile relief grinding attachment with software.

SAMPUTENSILI S 1000GW

Technical Specification S375G
Max. work piece diameter 375 mm
Profile Depth Range
-dressable tools 1.5 – 35 mm
-electroplated tools 0.5 – 50 mm
Max. Helix angle (autom. positioning) ±90 °
Max. distance between centers 1,000 mm
Max. length of work piece to be ground
-max. wheel dia./min. work piece dia 600 mm
-max. wheel dia./max. work piece dia 400 mm
Max. speed of grinding spindle 18,000 rpm
Max. speed of work spindle 300 rpm
Grinding spindle motor output 11 kw
Total connected load of machine 50 kVA
Machine dimensions, L x W x H 5.80 x 4.80 x 2.70 m

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 centre

    • Gildemeister Linear CTX 620, with Siemens 840D system with Shopturn Software.
Technical Specification CTX 620
Cross Travel (X) 382 mm
Vertical Travel (Y) ±65 mm
Longitudinal Travel (Z) 1,100 mm
Bar feed 121 mm
Chuck Diameter 400 / 500 mm
No. of total stations 12 + 6 mm
  • Shanthi Mill Turn 250Y Linear with Siemens 840D system with Shopturn Software.
  • CNC Hard turning machine 2 Nos.
  • Shanthi Hard Turn 210 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
  • Shanthi Speed Turn 165 with Siemens 802D system.
  • 30 Nos of 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 8000mm (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

Technical Specification CVT – 150 F
Table diameter 1500 mm
Maximum swing diameter 1600 mm
Height under cross rail 750 mm
Vertical traverse of Turret Head ( Z – axis) 700mm
Horizontal traverse of Turret Head ( X – axis )
-To left of table center 40 mm
-To right of table center 880 mm
Maximum load of table (symmetrical) 8000 kg
Face Turret Positions 5

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

CNC Universal Grinding Machines with “MOVOMATIC” controller

    • 2 Nos. Studer S33 CNC Universal Grinding
Technical Specification S33
Distance Between Centers 1000 mm
Center Height 175 mm
    • Kellenberger UR 175/1000 CNC Universal Grinding
Technical Specification UR 175/1000
Distance Between Centers 1000 mm
Center Height 175 mm

CNC Internal Grinding Machine

    • HMT model GC 225 CNC Internal Grinding
Technical Specification GC 225
Distance Between Centers 600 mm
Center Height 225 mm
  • 2 Nos. Studer S151 CNC Internal & Face Grinding

Internal Grinding Machines

Total 20 Nos. – max. Ø1000 mm bore (Make – Sielemann, Voumard, Overbeck, einecker, 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

  • 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.

Vision, Mission, Ethos


Vision

To be the No.1 company that manufacturers Gears, Gear Boxes, Geared Motors, Gear Assemblies both standard and custom-built to customers’ expectation.

Mission

By recognizing manpower as the prime mover to organizational goals, we duly motivate them to do their jobs “extra-ordinarily well” with “optimum creativity and productivity”

Ethos

Shanthi Gears is firmly committed to achieve customer delight by.

  • Deliver the best products at the most economic prices
  • Ensure prompt delivery
  • Follow fair minded business practices for the good of all stake holders

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