Aluminum Gears

We are manufacturers and exporters of Aluminium gears. Since its beginning, Ashoka group is involved with the manufacturing a wide range of aluminium gears for industrial and commercial markets , which are used in a wide variety of applications. Aluminium is widely used for light duty instrument gears.

Aluminium is lightweight, non-corrosive and easy to machine. The metal is malleable and has non-magnetic characteristics, it can be molded to any shape. Aluminium gears can be of various shapes. It offers spark proof starting of the engine and offers high strength. It offer smoother running, longer life and silent operation. It is protected with a coating of anodize. They are designed to resist wear for long lasting durability and maximum performance.

The quality of our aluminum gears is regularly checked at every stage from manufacturing to final dispatch. Our long industry experience enable us to manufacture and supply these gears according to customer's drawings and specifications.

Wood Gears

Ashoka group specializes in manufacturing and exporting a range of wooden gears. They are widely used in textile mills and other industrial operations. They are also used in clocks, flour mills and coal mines. Wooden gears are manufactured by making a blank out of wood, drilling the shaft hole and filling a key way in the wood. Then using a gear train at slow speed, long pieces of brass shim stock trimmed to the width of the gear is fed in between a pair of moving gears.

This forms the brass with the proper gear tooth shape. The brass with the tooth pattern is wrapped around the wooden blank, overlapped one tooth and soldered together. The wood with brass wrapped around it is then laid down on wax paper and the space between the brass teeth and the wood is filled with epoxy or fiberglass resin to harden the gear. It is then dried and trimmed up of excess epoxy. Gears made of wood are not so durable but they run smoothly and are easier to repair. We use mahogany or hard wood or other superior quality wood for the wooden gears to lend good hardness for resisting wear. Available in a variety of different models, our wooden gears have robust construction.

Brass Gears

Brass gears are one of the most widely demanded gears produced by Ashoka Technologies. We are one of the acclaimed companies engaged in manufacturing these gears.

An advantage of brass gear is that constant meshing work hardens their teeth. Brass gears are also used in locomotives, clocks and in all thermal industries. They are often used in clocks where they work well without any lubricant.

The metal has low cost, non-corrosive property and is easy to machine. We use the best quality brass to make our gears. All the properties of brass like good strength, hardness, good electrical conductivity, good corrosion resistance are inherent in our gears. We manufacture durable and highly efficient Brass gears. Our brass gears can be customized as per the specifications and requirements of our customers who are spread all across the globe.

Ground Gears

We specialize in the field of manufacturing and exporting of highest quality ground gears as per Customer specifications upto 45 degree angle

Our manufacturing capacity is :-
Module:- 0.5 to 4 Module
Diameter:- 10mm to 200 mm,
HELIX ANKLE:- 0 degree to 45 degree RH/LH

Features:

• Smooth finishes
• High transmission accuracy
• Higher load capacity
• Maximum efficiency

Profile:- Standard & Non
Lead & profile graph can be provided

Pinion Gears

We offer a widely appreciated range of pinion gears and helical pinion gears that are highly reliable and durable. Manufactured using superior quality material, our automotive pinion gear boxes are hugely demanded amongst wide clientele.

Features

• Use of cutting edge technology.
• Duly hardened and tempered.
• Available in various sizes for improving vehicle and steering response.
• Our automotive pinion gears use tooth modifications system in gearing to improve service life of pinions.

Spider Gears Provide Open Differential With Greater Performance

Spider gears are an integral part of you differential. They are part of the gear set that allows your rear wheels to turn at different speeds, which is necessary for many instances. When your vehicle goes into a turn, the out wheel turns at a faster rate than the inner wheel; this is accomplished through a series of gears including spider gears.

Spider gears offer you the ability to turn your vehicle without feeling the rear end bump as you go around a turn. If it weren't for spider gears and side gears within the differential, both rear wheels would turn at the same speed. If you're only going straight, this is not a bad thing, but the moment you go into a turn, the outside wheel will try to speed up. If spider gears and side gears where not in place, that outer wheel would not be able to turn faster than the inner wheel and would actually drag as you went through the turn, producing a bumping, lurching motion.

Spider gears are provided in the differential from the manufacturer and are one of the many shapes that gears can come in. Unlike spur gears, spider gears meet the shaft or other gear at a right angle, allowing them to be seated on shafts that do not touch and allowing the differential to be smaller and yet provide the necessary performance for most applications. Aftermarket, or performance differentials, have differently sized spider gears as well as differential housing to provide better traction for harder usage.

Spider gears are employed in limited slip differentials as well as standard differentials. Within a limited slip differential, spider gears work in conjunction with clutch packs to reduce the speed of a wheel that is spinning much faster than the other. The purpose of the clutch packs is an attempt to keep both rear wheels at relatively the same speed. Their efforts aren't noticeable when you're simply taking a curve, but if one wheel where to be placed on ice or in slick mud, the opposite wheel would be able to grip the road.

A standard differential allows all the torque to go to the wheel with the least amount of resistance; while this isn't a bad thing for street driving, if you intend to take your vehicle off road, or consistently drive in areas where little traction and slick spots are common, a limited slip differential, or fully locking differential is a better choice. The spider gears within these differentials are much larger and made much thicker than they are within standard differentials. With a standard differential, the wheel that has the least amount of traction will get the largest amount of spin, leaving your vehicle sitting still. A limited slip differential is designed to stop that, allowing much more torque to go to the wheel with traction.

Spider gears are one of the modern innovations that allow limited slip differentials to operate. Interestingly, they also play a vital role in locking differentials and standard differentials, as well.

Worm Gear Drives: Quiet, Efficient Performance

Worm gear drives offer many benefits. They take up little space, offer quiet operation and have been used in many different applications. Worm gear drives provide extreme benefits where size is a problem Traditional spur gears would take up considerably more room than what can be accomplished with a simple worm gearbox. They also take advantage of all the major forms of gearing to suit almost any application.

Worm gear drives offer great operation for many different uses. You'll find them in use in use in the mining industry, in ship's rudders and all types of presses. Worm drives offer a great way to amplify a limited amount of torque, though heat can cause them to become less efficient. Worm gears are also used in a limited amount of automotive differentials, though it has fallen out of favor with many manufacturers. Hummer is one of the manufacturers that still utilizes worm gears in their differential, specifically their military vehicles, though some civilian applications have worm gears, as well.

Worm gears were replaced in open differential due to problems with reduction ratios, though many all wheel drive vehicles continue to use worm gear drives in their applications. Large trucks used for hauling very heavy loads often utilize worm gear drives in their differentials, though they require very large differential housings to accommodate the amount of differential fluid needed to dissipate the heat created by the worm gear drive itself.

A worm gear drive consists of two main parts: the worm gear itself, which looks much like a spur gear and the worm, which is a gear shaped like a screw. The benefits that a worm gear drive offers are due to the fact that each revolution of the worm turns the worm gear a whole tooth; this allows them to greatly amplify torque in their relative settings.

Possibly the single best example of a worm gear is the adjustable screw clamp, called a jubilee clamp. These are found almost everywhere and most people are familiar with their appearance. Other forms of the worm gear drive exist, but this is the single most recognizable form that they take. The best applications for a worm gear drive are those in manufacturing industries where greater torque, in a smaller package is required. Since the worm gear drive is able to be set up at right angles to the input shaft, the length of the equipment is significantly reduced. Many industries find that the non-reversible motion is a great benefit, as well. Since the worm can only drive the gear, it means that they can only be used as speed reducers, rather than speed enhancers. The gear cannot drive the worm in a worm gear drive.

Due to these factors, they are an ideal way of decreasing speed, yet increasing power in smaller equipment. While there are many different applications for worm gear drives around the world today, small electric motors are possibly the area that they benefit the most, though musical instruments have been the longest running beneficiary of these devices.

Gear Cutting Is All About Hobbing, Shaping and Grinding

There are several methods that are used in gear cutting. The first one is gear hobbing, where the hobber die and the gear blank are rotated at the same time and speed, when the profile of the hob is transferred on to the gear blank. A milling machine or a jig grinder is used to cut spur and other straight gears. This mechanism makes use of gear cutters that are numbered, along with indexing head or rotary table. The tooth count of the gear forms the basis in determining the number of gear cutters used, and any of the straight gears can be produced this way.

When machining a helical gear, or twist drill, on a machine that is operated manually, a true indexing fixture needs to be used. The indexing fixture would be required to be taken off from the drive worm, and fixed with a gear-train to the machine table, which can then be operated as a carriage on the lathe. With this kind of a system set up, while the machine table moves on the x-axis, the fixture would be moving at a fixed accurate incremental ratio with respect to the table. The machine table would move in a highly controlled manner via the index plate, producing a precision linear movement, such as, a vernier scale.

The gear-cutting tool comprises of a cutter body member, which has a circular shape, a front and a back surface, and an axis on which it rotates. An outer section of this cutter body has several individual projections, arranged equally spaced from each other around the cutter body. The spaces between the projections are so arranged that they can receive the slots for the cutting blades.

There are several machines which are used in gear cutting, and these are briefly mentioned below:

Hobbing Machine
This is a special kind of milling machine, which is used for cutting gears. It is the major machine with is essentially used for spur gears of involute form. This process uses the method of rotating the gear blank and the cutter at the same time, maintaining a fixed ratio between the cutter and the gear blank.

Gear Shaper
For cutting the internal and external gear teeth, a gear shaper machine tool is used. The name "shaper "comes from the action of the machine itself, where the concerned part is engaged on the forward stroke of the cutter, and pulls away from the part on the return stroke. The cutting tool of the shaper has the same pitch that of the gear to be cut.

Gear Grinder
This tool is used to automatically grind a helical gear. A drive source in this machine tool drives a rotating grinding wheel. A second rotating driving source is used to rotate a helical gear, meshed with the teeth on the grinding wheel. The third driving source in the machine tool displaces the helical gear and the second drive source simultaneously. Two pulse generators are used, which are connected to the first and the third drive sources. The pulse output from one is subtracted from the output of the other, and this differential is applied as the drive pulses for the second rotational drive.

Gear Reduction Is the Major Application of Gear Coupling

Gears are seldom used as a single entity. Almost all machines have gears working in pairs. Gear coupling has the following advantages:

Gear Reduction
Gear reduction is the major application of Gear coupling. The motor, which supplies the power to the system usually, has high power but lacks the essential torque required for work. In order to increase its torque the motor is connected directly to a small gear that is coupled with a larger gear. This results in an increase in torque at the expense of speed. Gear reduction is used in cars to convert the power of the motor into higher torque for motion of the wheels along the surface of the road.

Change in Direction of Movement
Most often the direction of application of torque is different than the direction of movement of the supply. The change in direction can be brought about by using gear coupling consisting of a system of two or more bevel gears. An example is the gear differential used in vehicles.

Change in Axis of Motion
When the rotary motion is to be changed to a different axis, gear coupling is used. Two or more gears are coupled in the same plane to change the axis of rotation. Either spur or helical gears can be used for this purpose. Helical gears are preferred as they work more silently in comparison to spur gears. An example is a windmill where the blades and motor are on different axis of rotation.

Change of Rotary to Linear Motion
Industrial machines like conveyor belts require conversion of the rotary motion of the motor to vertical motion for the movement of material. This is brought about by using gear coupling of a rack and pinion gear. The motor is connected to a small pinion gear which moves the rack gear for linear motion. This type of gear coupling is also using in crushers and water pumps.

Fixed Gear Bicycle

The first question that comes to your mind is what a fixed gear is. This term usually applied to bicycles, which have only one gear. This means that there is only one chain-ring fitted to the cranks, and at the back it has only one sprocket. These two are kept tensioned by a single loop of chain. There is no free-wheel mechanism, and this means that you cannot stop pedaling while the bike is in motion. The forward motion of the bike makes the pedals rotate independently.

Fixed gear provides only one gear ratio. This type of gear is mainly found in bicycles, which is also called a fixed-wheel bicycle, where the free-wheel is not present and runs on only one gear ratio. Fixed gear bicycles cannot coast owing the reason that there is no fixed-wheel mechanism, with the result that the pedals run in the same direction as that of the rear wheel. The rider of the bicycle can only restrict the pedal movement in order to stop the bike without having to apply the brake.

Generally, fixed gear bicycles have one gear ratio. Some are fitted with sprockets on each side of the hub, which provide the use of two gear ratios. There could be fixed gear on each side of the hub, or a fixed gear on one side with a free-wheel gear on the other. In case of a 42 teeth chain-ring there could be 19 teeth on the sprocket on one side, with the other having 17. This makes the gear in the later about 11% to 12% higher than the former.

There are distinct advantages of a fixed gear bicycle. In this type of a bike, either side of the drive drain has one cog each, there are no bearings or pawls in the free-wheel, and there is no deraillurs chain to apply the tension. This brings down the weight of the bike to quite an extent, which provides ease of riding and requiring less force to move forward. The drive system of the bike is direct, owing to the absence of the deraillurs, which would mean that, it provides you with increased pedaling efficiency. Your legs feel the traction between the rear tyre and the road. This makes the bike much ore safe to ride in snow and ice. This is the other great advantage in a fixed gear bike.

In normal bikes, the force on the pedals creates a linear motion to the bike. The pedal in this kind of a bike is connected to the chain-ring, which is the front sprocket. It is connected by cams, which translates the force on the pedals to a torque, and this rotates the chain. Where-as, in a fixed gear bicycle the pedals are directly connected to the rear wheel, and the force that is applied to the pedals makes the rear wheel to rotate. Under the circumstances, a fixed gear bicycle can be ridden backwards too. In this situation, the rider can apply the brake or slow down the bike only by restricting pedal movement.

The Most Commonly Seen Examples of Gears -- Bicycle Gears

Bicycles are machines that mostly attract the interest of the kids. It is a machine which lets you travel faster to destinations using the minimum of energy, compared to the energy that you would spend by walking or running to reach the place that you would want to go to. The mechanics that drive the bicycle are all open and exposed, and none of the machineries used are covered with sheet metal. Many of the kids, having curiosity in mechanical tendencies, cannot help but take their bike apart and put it back again.

You might have seen bicycles ridden in the movies or in a circus, where the front and the rear wheels of the bicycle have a funny "penny-farthing" shape. The bicycle used usually had a huge front wheel and a tiny wheel at the back. This type of bicycle appeared in the year 1870, but by the end of the century the bicycle was replaced by what we see normally these days. Just as we find in a kid's tri-cycle, the front wheel of the penny-farthing bicycle is directly connected. This would mean that as you pedal once, the wheel goes through one revolution. If the front wheel of the tri-cycle is taken as 16 inches, the circumference of the wheel comes to 50 inches. Therefore, with each revolution of the pedal, the front wheel travels through 50 inches. Pedaling at the rate of 60 rpm, the tri-cycle would be moving 50 inches per second, which comes to about 2.8 mph. If the pedaling goes up to 120 rpm, which is very unlikely, the tri-cycle would be moving at 5 mph.

The concept of gears in bicycles came from the fact that, it provides the rider with the facility to move faster without pedaling rapidly. If you take an example of a normal bike, the wheels are 26 inches in diameter. With the front chain wheel having 22 teeth and the rear having 30, a bike would have the lowest gear ratio. This would give a gear ratio of 0.73:1, meaning that with each pedal revolution, the front wheel would turn 0.73 times. This would make the bike move forward 60 inches with each pedal stroke. This comes to about 3.4 mph with 60 rpm of pedal revolution.

In the same way, the highest gear ratio in a bike is achieved with the front wheel chain having 44 teeth, and the rear wheel having 11 teeth, which provides a gear ratio of 4:1. Therefore, with 26 inches diameter of the front wheel, the bicycle moves forward by 326 inches with each pedal revolution. If the pedaling is done at 60 rpm, the bike would move forward at a speed of 18.5 mph. If the pedal speed can be doubled to the maximum of 120 rpm, the maximum speed of 37 mph could be attained. The speed range from 3.4 mph to 37 mph is an attractive feature, and that is the reason why bicycles have gears.

The gears at the front of the bicycle are known as chain wheels. This, what is called freewheel, is attached to the rear wheel. Depending upon what kind of a bicycle you have, the freewheel has 5 to 9 gears on it. There is only one direction that the freewheel can spin, and it is locked in the other. This way you can either pedal or you cannot.

There are two derailleurs at the front and back of a bicycle. These are used for changing the gears. The two small cogs at the rear derailleur spin freely. The tension of the chain is maintained by the arm and the lower cog of the derailleur. A spring holds back the cog and the arm. By shifting the gear, you are simply putting the chain on a different ring. Changing the left shifter, the ring at the pedal changes. There are three rings, where the smallest one is 1, the middle one is 2, and the third one is 3. By shifting down, you are changing to the smaller ring. To change the rings on the rear wheel, you use the right shifter, where the biggest ring is 1, and the largest is 6. There are markers in both the right and the left shift, and you can sift any of the shifters looking at the numbers.

Inside a Bevel Gearbox

Gears are used for changing the direction of rotary motion or to increase the torque. Industrial machines typically use a bevel gearbox for these purposes. Let us see the inner construction of a simple bevel gearbox and understand its mechanism.

A Peep Inside a Bevel Gearbox
On opening the housing of a bevel gearbox one comes to know that the construction is really simple. It consists of an input gear coupled with another gear called the output gear at right angles to each other. The gears can be either of spur or helical type. Helical gears are preferred as they are less noisy due to gradual engagement and have a longer life.

In case a reduction in speed is required, the diameter of the output gear is kept larger than that of the pinion. If only change in direction is required the diameters of both the gears are equal.

Materials commonly used are plastic or metal and depend on the load. Three gears are used in case the axis of rotation the same as that of input. The point of contact is well lubricated with gear oil.

Mechanism of a Bevel Gearbox
The electric motor or engine causes the input gear to spin which in turn rotates the output gear. Thus the rotary motion is passed on from the input arm to the output arm.

In case the diameter the output gear is larger than that of the input gear, the torque of the system increases at the expense of speed. Such a system is known as a reducer. The gears are at right angles to each other and hence the direction of the rotary motion is changed.

Applications of a Bevel Gearbox
The property of change of axis and speed of the bevel gearbox is used in a variety of industrial and automotive machines. It is used in turbines, pumps, grinders, etc. In vehicles the gearbox is used in the limited slip differential. One can clearly understand the working of the bevel gearbox by opening a simple hand drill.

Construction and Working of a Bevel Gear Reducer

One of the major applications of gears is gear reduction. The high power and low torque of the supply can be converted into high torque by coupling of a smaller input gear with a larger gear. There are different types of gear reducers depending on the types of gears coupled viz. worm gear reducer, spur gear reducer, bevel gear reducer etc.

Construction of a Bevel Gear Reducer
A bevel gear reducer consists of a small gear acting as a pinion coupled with another gear of a larger diameter at right angles to each other. The gears can be either of spur or helical type. Helical gears are preferred as they are less noisy due to gradual engagement. The material can be either plastic or metal depending on the application. Three gears can be used in case we need to keep the axis of rotation the same as that of input. The whole arrangement is sealed in a metal or plastic casing known as housing. The point of contact is lubricated with gear oil.

Working of a Bevel Gear Reducer
The diameter of the output being larger than that of the input gear, the torque of the system is increased at the expense of speed. Since the speed is decreased, this system is known as a reducer. The gears are at right angles to each other and hence the direction of the rotary motion is changed.

Advantages of a Bevel Gear Reducer
The efficiency of a bevel gear reducer is higher than that of a typical worm gear reducer. The bevel gears have high load capacity.

Applications of a Bevel Gear Reducer
Due to change in direction of the rotary motion the bevel gear reducer finds a variety of applications in industry and automotives. In industries it is used in turbines, pumps, cranks, etc. In automotives it is used in ordinary as well as limited slip differentials.