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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

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TECHNICAL SPECIFICATION FOR TRACTION GEARS
OF DIESEL ELECTRIC LOCOMOTIVES

fofkf"V la[;k pk0k0- 0-2800-17 (lakks/ku - 0-00)

tuo'h 2004
SPECIFICATION NO. MP. 0. 2800.17 (REV.-0.00)
JANUARY, 2004

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ekud uxj] y[ku - 226 011
RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW - 226011.

SPECIFICATION NO. MP-0.2800.17

TECHNICAL SPECIFICATION FOR CASE CARBURISED GEARS AND

PINIONS FOR DIESEL ELECTRIC LOCOMOTIVES.
0.

FOREWARD
Traction gears constitute vital part of the power transmission system of
locomotives and call for sophisticated techniques in manufacture, with
special material, equipment and quality control requirements.

1.0

SCOPE
This specification is applicable for traction gears and pinions used in diesel
electric locomotives listed at Annexure 'A'. It covers technical requirements
of manufacture and supply from raw material to finished stage.

2.0

MATERIAL

2.1

Gears and pinions shall be manufactured from forging quality steel made by
open hearth, electric, duplex, basic oxygen or a combination of these
processes. The steel shall be fully killed and homogeneous .The steel shall
also be subjected to secondary refining including vacuum degassing.
Sufficient discard shall be made from each ingot to ensure freedom from
pipe, harmful segregation and other defects.

2.2

Chemical Composition & Physical Properties:

The pinions and gears shall be manufactured from steel grade
15Ni7Cr4Mo2 TO
IS: 4432-1988 (Indian Standard Specification, First
Revision for Case Hardening Steel.)

2.3

The inclusion rating of the steel shall not exceed 2.0 A, 2.0 B, 2.0 C & 2.0 D
for both thick and thin series. The field of each type of inclusion shall be
determined in accordance with IS: 4163 and shall be taken as the rating.

2.4

Physical properties and chemical composition of the steel used shall conform
to the relevant material specification.

2.5

In case of steel to any other composition, prior approval of RDSO shall

obtained.

3.0

MANUFACTURING OF FORGED BLANK

3.1

The gear and pinion shall be manufactured by rolling/forging ingots in to

blooms / billets / bars (made from adequately rolled / forged cropped ingots)
to the blank stage, followed by closed die or upset forging, or peripheral
forging. The ratio of reduction at different stages shall be as follows:

a)

The minimum-reduction ratio from the minimum section of the ingot to

maximum section of the round bloom / billet by forging shall be 4:1.

be

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SPECIFICATION NO. MP-0.2800.17

b)

The gear blanks shall be made by a process of upset forging, followed by

peripheral forging under a power hammer or press. The reduction ratio in
height by upset forging from round bloom/bar to the gears blank shall be at
least 4:1.

c)

The forging and rolling processes shall be performed in such a manner, that
the central axis coincides with the axis of the gear wheel.

d)

The semi-product (bloom) intended for the manufacture of forged blanks of

gears/pinions shall be obtained from cropped ingots, without any pipe.

e)

In case only forged blanks are purchased, the manufacturer shall ensure free
access of the inspecting authority at his works for the satisfaction of the latter
that the material is being supplied in accordance with this specification.

4.0

FORGED BLANKS FREE FROM DEFECTS:

4.1

Billets, blooms, slabs and bars shall be free from cracks, surface flaws, laps,
rough, jagged and imperfect edges and all other surface defects which may
result in defects in the forging made there from.

4.2

The pre machined gears and pinions shall be free from cracks, lap or any
other harmful surface or internal defects.

4.3

No welding shall be permitted on the forged blank. The outside surfaces of

the forged blanks shall not show any flaw, cracks, fold or other injurious
defects. The forged blanks shall be provided with adequate allowance for
machining all over, and shall suitably be annealed to facilitate subsequent
machining.

4.4

Forging supplier shall furnish test report showing the Mill source, Chemical
composition, inclusion rating of material, forging ratio and grain flow pattern
of gear and pinion blanks supplied to the gears manufacturer.

4.5

A photograph of grain flow pattern of forging blank of pinion and gear should
be submitted prior to prototype inspection by RDSO.

5.0

TESTS ON ROUGH FORGED GEAR BLANKS:

5.1

Macro etch test: The macroetch examination shall be done as per ASTME381 (method of Macroetch testing & inspection of steel forging). The
macroetched section shall reveal satisfactory flow line pattern right up to the
centre of the forged blank.

5.2

Grain size: The grain size of forging when tested in accordance with
IS/2853/ Latest Version shall be in the range of 5 to 8 inherently fine-grained
structure. This is as per IS 4432 -1988.

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SPECIFICATION NO. MP-0.2800.17

5.3

Ultrasonic Test: All forged blanks, before and after machining is performed
on them, shall be tested ultrasonically for ensuring freedom from casting and
forging defects. A tentative standard for Ultrasonic Testing and criteria for
acceptance/ rejection of the gear/ gear blanks is given at Appendix A.

5.4

Hardness Test: The forging when tested in accordance with IS- 1500 shall
show a hardness value of 170 220 HB.

6.0

PRE-MACHINING HEAT TREATMENT OF FORGED BLANKS

6.1

To relieve the residual, forging stresses, the forging shall be normalised at

840C - 870C .The soaking time shall be given according to ruling thickness
forged blank.

7.0

MACHINING: - as per clause 9.0.

8.0

HEAT TREATMENT

8.1

Case Hardening:
The active tooth surface of the gear/pinion shall be suitably case carburised,
hardened and tempered to obtain the specified case depth, case hardness
and physical properties of core.

8.2.1

Effective Case Depth:

8.2.1.1

Definition and Measurement:

The effective case depth is defined as that at which a hardness of 500 HV 30
(50 RC) is obtained. The depth is measured perpendicularly inwards from
the surface. The available case depth after finish grinding shall be 1.8mm
minimum or as mentioned in relevant drawing.

8.2.1.2

Case Depth of Carburised and Hardened Gears:

For checking the case depth, one spy-piece shall be provided per container
when box carburising and, at least, one but preferably two (towards top and
bottom of furnace) when gas carburising. The spy-piece shall be of a section,
which adequately simulates that of the teeth, which it represents and shall be
placed near to but not on the gear teeth. The spy-piece shall be of the same
material from which the gears are made.
After carburising, the spy-piece shall be hardened and tempered along with
the gears it represents, and then broken. Hardness survey of the case shall
be carried out after grinding and polishing as per IS: 6416 (Method of
measuring case depth of steel). The results shall be as specified in Clause
8.2.1.1
Alternatively, the end of the teeth remote from the traction motor side may be
ground back at an angle to reveal the case for visual examination or
hardness testing.

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SPECIFICATION NO. MP-0.2800.17

8.2.2

Hardness of Case-hardened Layer:

Surface hardness of the gear after grinding measured at tip, flank or root
shall not be less than 650 HV 30 or 58 RC (620 HB). For the position where
the effective case depth is measured on either spy-piece or gear the
hardness shall not be less than 500 HV 30 (50 RC).

8.2.3

Micro Examination:
At least one spy-piece per carburising batch shall be microscopically
examined for establishing absence of cementite network and free cementite.
Retained austenite content of 15% - 30% may be permitted in the carburised
zone. This is as per IS 4432 - 1988.

9.0

GENERAL GUIDE LINES FOR MACHINING OF ALL TYPES OF GEARS

AND PINIONS

9.1

Bore of the pinions / gears is referred to as the fitting surface.

9.2

Fitting surfaces of the gear and pinion shall be ground finished before finish
grinding the teeth.

9.3

The surface texture of the fitting surfaces of gear and pinion shall not
coarser than the values specified in the relevant drawings.

9.4

The gear teeth shall be of involute profile, cut and ground on gear generating
machines. Protuberance cutter shall be used for generating the teeth for
automatically producing the most suitable stock allowance for grinding and
generating simultaneously the largest possible tooth fillet of semi-circular
shape with absolute uniform transition for the involute tooth flank to the tooth
root after grinding. No discontinuity/ Step formation from the ground tooth
flank and the machined root fillet shall be permitted.

9.5

The tooth profile shall be given the 'tip' and `root` relief in accordance with the
specification mentioned in the relevant drawings. The longitudinal crowning
shall be provided as specified in the relevant drawings.

9.6

The dimensions, tolerances and surface finish specified in the relevant

drawings shall be strictly adhered to. The following errors/ deviations shall be
measured as per gear/pinion relevant drawings.

be

a) Over all dimensions.

b) Individual error of pitch.
b) Consecutive error of pitch.
c) Cumulative error of pitch.
d) Profile error.
e) Alignment error.
f) Radial Run out.

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SPECIFICATION NO. MP-0.2800.17

9.7

The gear / pinion should be free from sharp edges.

9.8

The working face of the teeth shall be free from defects such as
heterogeneity in metal and forging / cutting / grinding imperfections. Any
repair of these surface defects shall be prohibited.

9.9

The end faces of the teeth shall also not show defects similar to Clause
9.8 particularly near the root circle.

10.0

SHOT PEENING:
Shot penning should be done on fillet radius and root of gears before
grinding, to impart compressive stress. All tooth surfaces should be protected
against peening or should be as per relevant drawings requirements. Use
S330 hard shot to obtain 200% minimum coverage in root area. Peening
intensity should be between 0.007 to 0.010 C.or shall conform to the relevant
drawings.

11.0

TESTS

11.1

Physical Testing on Material:

11.1.1

The following tests shall be conducted at the works of the gear manufacturer
or in an approved test house at
the cost of manufacturer on the test
samples selected as per Clause 11.1.2. At least, one sample per cast shall
be subjected to the following tests:
i) Ultimate tensile strength.
ii) Yield stress.
iii) Elongation percentage.

11.1.2

Test Sample:
The test sample shall be made in the form of a bar from a bloom of relevant
cast selected at random, shall be first forged down to 1/4 of the original
section and then a test bar of diameter as per relevant material specification
shall be turned from the forging.
This test bar shall then be heat treated (blank carburising, hardening and
tempering) along with the gear / pinions of the same cast as indicated in
Clause 11.1.1 and then the test piece machined .It shall carry the following
markings for identifications:
(a) Steel used
(b) The cast number / Heat no.

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SPECIFICATION NO. MP-0.2800.17

NOTE: (i) Blank carburising means the thermal treatment associated

with
carburising as applied to a test piece without using any carburising
medium.
(II) Tests on bar stock: - one bar stock shall be cut in the presence of the
inspecting authority and macro list shall be carried out to determined
if sufficient working as defined in this specification has been done as
the ingot to obtain the bar stock.
(iii) Test sample shall be repeated at an interval of every three years and
also whenever the failures of gear and pinion takes place.
11.1.3

Chemical composition & Physical properties:

One test sample per cast shall be chosen for chemical composition. The
analysis of steel shall be carried out either by method specified in IS: 228
Method of chemical analysis of steel and its relevant parts of any other
established instrumental method (Spectrometer). The chemical composition
and physical test results shall confirm to the relevant material specification.
The chemical composition and physical test result shall conform to the
relevant material specification .If any one of the test sample fail to meet the
requirement as mentioned in relevant material specification, the entire lot
shall be rejected.
In the events of rejection of entire lot, the lot offered shall be made unusable
in presence of purchasing / inspecting authority. However approving /
purchasing authority reserves the right to repeat the tests at their discretion
at certain time interval.

11.2

TESTS ON FINISHED GEARS: a)

Type Tests: - These will be conducted by RDSO on prototype gears

whenever a new source is to be approved. The lot offered for prototype
tests should not have less than 6 gears. These shall also be conducted
once in every three years after approval of prototype at any instance and
deemed necessary by RDSO. The following tests shall be conducted in
addition to acceptance tests mentioned at Para 11.2(b) and other tests
laid down in relevant specifications.
(i) Material test: Confirmation of the properties of material as mentioned
in material relevant specification are mandatory for product approval or
approval of manufacturer. It will be carried out in presence of RDSO
representative.
(ii) Hardness Check: The hardened teeth of all gears, after appropriate
heat treatment, shall be tested for surface hardness .The hardness shall
be measured at four equidistant points in the proximity of the root circle of
the teeth. The average value of four readings shall conform to the values
specified in Clause 8.2.2.The variation between the maximum and
minimum values shall not exceed 20 points HV.
Page 6 of 10

SPECIFICATION NO. MP-0.2800.17

(iii) Crack Detection check: All the finished gears/pinions should be

subjected to crack detection by suitable method such as magnetic particle
test, die-penetrate test or fluorescent test. On the discretion of inspection
authority. Ultrasonic testing on rim & hub portion can also be employed
to check any internal cracks in the forged & finished gears / pinions.
(iv) Dimensional & Tolerance checks: The finished gears shall be
checked for dimensional accuracies, tolerance, surface finish and tooth
errors / deviations as per clause 9.6.
If any one of the gears fails to meet the requirement as mentioned in
relevant material specification and dimension of drawing, the entire lot
shall be rejected.
(b) Acceptance Tests (During Routine inspection): - These are the tests
to be conducted, during routine inspection by purchaser / RITES against
individual orders:
a)
b)
c)
d)

Overall dimensions check.

Hardness check.
Crack detection test.
Tooth error/ deviations as per gear/ pinion relevant drgs.

During Routine inspection, inspection authorities shall check 30% of

gears & pinions from the lot offered.
12.0

MARKING
Following information shall be etched or punched at the free side of the
gears, which shall be indeliable and clearly legible.
i) Name of the supplier.
ii) Date of manufacture e.g. 10/2004.
iii) No. of teeth & gear ratio.
iv) Drawing no.
v) Manufacturer Job Sr.No.
vi) Designation of Material.

Page 7 of 10

SPECIFICATION NO. MP-0.2800.17

13.0

Quality Assurance Plan

13.1

QAP shall be submitted by manufacturer before undertaking manufacture of

prototype and got approved by RDSO. The QAP should be framed in such a
manner so as to ensure inherent protection against the use of incorrect
machine parameters for case hardened gears. QAP shall also have the
following information.

13.2

The Q.A. plan should incorporate quality assurance activities planned for
manufacturing & supply of bull gear and pinion in order to fulfil specification
quality, requirements given in relevant gear/pinion drawings, specification,
standards & other applicable documents for it. It shall include detailed stage
inspection plan, agency carrying out the check, sampling lot and acceptance
limits. Frequency of various checks, details of nature of work involved in the
checks and records maintained regarding these checks shall be indicated.

13.3

Manufacturer shall on demand by the purchaser, make the records of checks

carried out during internal quality assurance available for scrutiny.

14.0

ACCEPTANCE OF FINISHED GEARS AND GUARANTEE

14.1

Unless otherwise agreed between the supplier and the purchaser, a

minimum 72 months (six years) guarantee of reliable service, shall be
ensured by the supplier. The supplier shall undertake to replace, as quickly
as possible, the defective gear/pinion on account of faulty material or
workmanship. If failure of a particular gear involves the failure of the other
mating gear/gears, the supplier shall also be responsible for the replacement
of the damaged gear/gears.

14.2

The Inspecting Officer shall inspect the gears at various stages of

manufacture for conformity with specifications as well as the finished
condition before authorising for delivery. However, this authorisation does
not relieve the supplier of his liability with respect to any imperfections,
which may appear subsequently.

15.0

PROTECTIONS AND PACKING

The gears/pinions shall be suitably protected against oxidation and corrosion
by three coats of ready mixed paint, brushing Bituminous black, to IS: 158
(Specification for ready mixed paint, brushing, bituminous black, lead free,
acid, alkali, water and heat resisting for general purpose) or with any other
approved anti-rust compound capable of being removed easily by white spirit
or kerosene oil, allowing sufficient drying time between each coat. After the
last coat has dried, the gear shall be covered with waterproof paper .The
gears / pinions shall then suitably be placed to prevent any damage during
transport and handling.

Page 8 of 10

SPECIFICATION NO. MP-0.2800.17

APPENDIX-A

TENTATIVE
STANDARD
FOR
ULTRASONIC
TESTING
ACCEPTANCE OF TRACTION GEARS AND PINIONS

AND

1.

Gears/pinions forgings shall be tested ultrasonically for soundness from one

of the two side (flat) faces. In case of gears the scanning could be restricted
to the rim portion. The scanning shall be done with a 2/2.5 MHz, 25 mm dia
probe. The ultrasonic test unit used shall be either Krautkramer 'USIP 10' or
any other instrument of similar or improved characteristics

2.

The range shall be so adjusted that the back echo from the opposite face for
a particular size of gear/pinion under test shall occur at the extreme end of
the screen and its amplitude shall be approximately 75% of the full screen
height. With this setting, the scanning shall be done by moving the probe
circumferentially. In case the radial thickness of the rim of the gear and that
of the pinion is considerable, the scanning may be done following multiple
concentric paths separated by one probe position.
Criteria for Acceptance/Rejection:

Any flaw indication, the amplitude of which is greater than 25% of that of
back echo obtained from an adjacent location, shall be rejected.

Flaw indications, the amplitude of which are less than 25% of back echo
obtained from adjacent location may be accepted provided the back echo at
that location is not less than 80% of the original and the total number of such
flaw indications obtained on that gear/pinion is less than 5 and each flaw is
separated from the other by more 25mm distance. Where there is a
continuous flaw indication, the spread of the flaw shall not cover more than
one probe position in any direction. Where such indications are obtained,
scanning should be done in all radial directions at that location to verify the
spread of flaw.

Where there is a flaw indication in the first quarter of the usable length of the
trace, the same shall be confirmed by a scan from the opposite face.

Where the back echoes is reduced to less than 80% of the original, the gear
shall be rejected.

Page 9 of 10

SPECIFICATION NO. MP-0.2800.17

ANNEXURE-A

CASE CARBURISED TRACTION GEARS AND PINIONS

FITTED ON DIESEL ELECTRIC LOCOMOTIVES
SR. NO.

DESCRIPTION
PINION

NO. OF TEETH

RDSO DRG. NO.

19

SKDP-3397 ALT3

1.

2.

3.

CLASS OF LOCOS

YDM4
GEAR

92

SKDP-3396 ALT2

PINION

18

SKDP-3443 ALT2
WDG3A
(For TM4906)

GEAR

74

SKDP-3444 ALT2
WDG3A locos with
Roller suspension
SKDP-3546 ALT1 Bearing arrangement.
(For TM4907)

GEAR

74

PINION

18

SKDP-3624 ALT1

GEAR

65

SKDP-3623 ALT1

GEAR

65

PINION

22

SKDP-3775

WDP1, WDM2,
WDM3A, WDM3C &
WDM3D
With Roller
suspension Bearing
arrangement
(For TM -4907)
WDM2,WDM3A,
WDM3C,WDM3D, &
WDP1
(For TM 4906 & TM
165)

SKDP3312 ALT2

4.

WDP3A
GEAR

61

SKDP-3419 ALT3

Page 10 of 10