This document discusses industrial gearboxes for the steel sector. It provides an overview of steel production in India and potential customers in the industry. The steel making process is described for ore-based, scrap-based, and strip-based steel production. Special requirements for gearboxes in the steel industry are outlined, including superior sealing, compact design, versatility, and withstanding high shock loads. Various gearbox applications in rolling mills and other steel production equipment are illustrated. The document concludes with the presenting company's strengths in machining and engineering capabilities, and provides a timeline of activities related to gearbox development for the steel industry.

1. INDUSTRIAL GEARBOXES FOR
STEEL SECTOR
PRESENTED BY
GAJANAN AVANTKAR
14-Apr-14 STEEL SECTOR 1
KIRLOSKAR PNEUMATIC CO. LIMITED
A Kirloskar Group Company

2. KPCL Mission, Vision & Values
14-Apr-14 2STEEL SECTOR

3. CONTENTS
14-Apr-14 3
 Steel Production in India
 Potential Customers
 Steel making Process
 Ore Based Steel
 Scrap based Steel
 Strips Based Products
 Special Requirements
 Gearbox Used
 Strengths
 Machining Capability
 Design Capability
 Milestones
STEEL SECTOR

4. STEEL PRODUCTION IN INDIA
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5. POTENTIAL CUSTOMERS
14-Apr-14 5
 Mukand Steel
 Bhushan Steel and Strips Limited
 Vizag Steel
 Mittal Corp. Limited
 FACOR Steels
 Tisco ( Tata Iron and Steel Corporation ltd)
 Essar Steel
 Jindal Vijaynagar Steels Ltd
 Jindal Strips Ltd
 JISCO
 Uttam Steels Ltd
 Ispat Industries Ltd
 Mahindra Ugine Steel Company Ltd
 Tata SSL Ltd
 Usha Ispat Ltd
 Kalyani Steel Ltd
 Electro Steel Castings Ltd
 Sesa Goa Ltd
 NMDC
 Lloyds SteeI Industries Ltd
Integrated Steel Plants:
 Bhilai Steel Plant (BSP) in Chhattisgarh
 Durgapur Steel Plant (DSP) in West Bengal
 Rourkela Steel Plant (RSP) in Orissa
 Bokaro Steel Plant (BSL) in Jharkhand
Special Steel Plants
 Alloy Steels Plants (ASP) in West Bengal
 Salem Steel Plant (SSP) in Tamil Nadu
 Visvesvaraya Iron and Steel Plant (VISL) in Karnataka
 Indian Iron and Steel Company (IISCO) in WB
 Maharashtra Elektrosmelt Limited (MEL) in Maharashtra
 Bhilai Oxygen Limited (BOL) in New Delhi
STEEL SECTOR

6. STEEL MAKING PROCESS
14-Apr-14 6
ORE BASED STEEL:
STEEL SECTOR

7. STEEL MAKING PROCESS
14-Apr-14 7
ORE BASED STEEL:
STEEL SECTOR

8. STEEL MAKING PROCESS
14-Apr-14 8
SCRAP BASED STEEL:
STEEL SECTOR

9. STEEL MAKING PROCESS
14-Apr-14 9
SCRAP BASED STEEL:
STEEL SECTOR

10. STEEL MAKING PROCESS
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STRIP PRODUCTS:
STEEL SECTOR

11. STEEL MAKING PROCESS
14-Apr-14 11
STRIP PRODUCTS:
STEEL SECTOR

12. SPECIAL REQUIREMENTS
14-Apr-14 12
SUPERIOR SEALING CAPABILITIES:
The steel industry, especially the rolling operations of a mill, is perhaps the
most demanding environment of any industry. To survive, a gearbox must protect itself
from heat, moisture, chemicals and air-borne contaminates.
If seal integrity is lost, the gearbox lubrication will be compromised. Once the
lubrication is lost or contaminated, bearing failure will result.
The following are the design criteria for the gearbox seal:
 Superior barrier to keep contaminates out of the
gearbox.
 Exceptional oil containment.
 Optional seal composition that will increase the
chemical resistance and operating temperature of the
gearbox.
STEEL SECTOR

13. SPECIAL REQUIREMENTS
14-Apr-14 13
COMPACT DESIGN:
It must be of compact, power-dense design, so that even high ratio units are
not bulky or heavy. Individual roll drive designs, in particular, are subject to restrictive
space limitations.
VERSATILITY:
To accommodate variations in design, motor requirements, input speeds and
ratios, the selected reducer must be very versatile.
The following criteria must be adaptable, allowing designers to develop a
configuration based upon system requirements:
 Motor Mounting
• Integral Motor
• C-Face Adapter with coupling
• C-Face Flange with hollow keyed I/P
• Top Mount
• Shovel Base Mount
 Mounting Configuration
• Foot Mount
• Wall Mount
• Flange Mount
STEEL SECTOR

14. SPECIAL REQUIREMENTS
14-Apr-14 14
HIGH SHOCK LOAD CAPABILITIES:
Non-uniform and heavy shock loads are considered normal operating
conditions. Many design engineers handle this requirement by increasing the service
factor of the gearbox.
According to the American Gear Manufactures Association (AGMA) selection
criteria, reducers can be selected by Service Factor or Load Classification. Both are a
means of classifying different equipment and applications into a uniform guideline
useful for reducer selection. For Metal Processing, AGMA makes the following
recommendations:
STEEL SECTOR
The following are the design criteria for
high shock load requirements:
 Service Factor no less than 1.25
 Ductile Iron housing to withstand high
shock
 Internal Component Design to include:
• Bearing Grade Steel, Heat Treated
• Strict Tolerances
• Precision Finish

15. GEARBOX USED
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ROLLING MILLS:
 Two-high : Two opposing rolls
 Three-high : Work passes through rolls in both directions
 Four-high : Backing rolls support smaller work rolls
 Cluster mill : Multiple backing rolls on smaller rolls
 Tandem rolling mill : Sequence of two-high mills
OTHER GEARBOXES:
 Uncoiler Gearbox
 Recoiler Gearbox
 Slitter Gearbox
 Anti Backlash Gearbox
 Bridle Drive Gearbox
 Calendar Gearbox
 Reversing Tube Mills
 Roll Adjustment Drive
 Continuous Casting Driver
 Roll Straightner
 Winding Machine
 Cooling Bed Transfer machine
 Continuous Shears
 Crank type Shears
 Plate Tilter
 Ingot Pusher
 Intermittent Roller Table
 Continuous Roller Table
STEEL SECTOR

16. GEARBOX USED
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Two-high Rolling Mill
STEEL SECTOR

17. GEARBOX USED
14-Apr-14 17
Two-high Rolling Mill
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18. GEARBOX USED
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Cluster Mill:
Tandem Mill:
Rolling mills have several stages, where the each stage successively reduces the thickness of
the stock until the desired cross section is achieved.
Multiple backing rolls allow even smaller roll diameters
STEEL SECTOR

19. STRENGTHS
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 Gear Hobbing 2000 mm ( 22 module )
 Gear Teeth Grinding 1500 mm
 Internal Gear Cutting / Grinding 1300 mm
 Horizontal Boring 5500 x 2000 x 1250 mm
 Vertical Boring 4000 x 3000 x 1250 mm
 CNC Turning Centers 1250 x 1100 x 1250 mm
 Case Carburizing & Hardening Furnace 1500 mm
 3 Axis Coordinate Measuring m/c can handle jobs of size 4000 x 2500 x 1500 mm – with accuracy
+/- 0.006 / meter.
 High precision CNC Controlled machines for Hobbing and Teeth Grinding and Bore Grinding.
 Modern tooling for Hobbing process like Gashing Cutter to reduce Machining time.
 Profile corrections and Addendum modifications provided on Gears.
MACHINING CAPABILITY Best suited for Heavy Engineering
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20. 14-Apr-14 20
ENGINEERING STRENGTH:
Products are always designed to meet & exceed customers expectations
with help of Strong & experienced Engineering Team
Design validations are carried out on latest softwares viz.
 ROMAX Designer R-14.0,
 KISSsoft - 2012 and KISSsys - 2012
 ANSYS Workbench – 14.0
 PRO-Engineer 3D Modeling
STRENGTHS
STEEL SECTOR

21. TIMELINE
14-Apr-14 21
Activity Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 Aug-15
Basic Design
Study
Developing
Expertise
Market
Study
Site
Visits
Gearbox Development
as New Product
Interim Catalogue
Development
Brand
Awareness
Design
Optimization
Process Optimization for
Lead Time Reduction
Process Optimization for
Cost Reduction
Final Catalogue
Development
Research and Engineering Activities
Marketing Activities
Manufacturing Engineering Activities
STEEL SECTOR

22. THANK YOU

23. www.kirloskarkpcl.com
KIRLOSKAR PNEUMATIC CO. LIMITED
A Kirloskar Group Company
14-Apr-14 23STEEL SECTOR