Hot-Selling Rotary Dryer Kiln Girth Gear for Mining
Product Description
Girth Gears: Rotary kiln Girth Gear,ball mill Girth Gear
Girth Gears offered find extensive application in different industry sectors including in sponge iron plants, steel & cement industry, mining industry, wind mills as well as in other industry sectors. These are made available in module range of 10 Module to 70 Module and in minimum diameters of 100 mm to 15000 mm. Further, these comprise maximum weight of 70 MT single pieces. Here the range of hardened & ground gear boxes/gears comprise Worm gear boxes, Helical / Double helical gears/gearboxes, Helical-Bevel gearboxes, Planetary Gearboxes and others.
ZTIC Gear Cutting Machines include:
Ø16m CNC Hobbing Machine
Ø12m Gear Cutting Machine (Switzerland)
Ø10m Hobbing Machine (Germany)
Ø4m CNC High Speed Hobbing Machine (Germany)
Ø1.6m Horizontal CHC Hobbing Machine (Germany)
Ø5m CNC Profile Gear Grinding Machine (Germany)
Ø2.8m CNC Profile Gear Grinding Machine (Germany)
Ø1.25m CNC Profile Gear Grinding Machine (Germany)
Ø1m CNC Profile Gear Grinding Machine (Germany)
Ø0.8m CNC Profile Gear Grinding Machine (Germany)
Automatic positioner
Module Range: 10 Module to 70 Module.
Diameter : Min 100 mm to16000 mm.
Weight : Max 120 MT single piece.
Hardened & Ground Gear Boxes/Gears:
Worm gear boxes
Helical / Double helical gears/gearboxes
Helical-Bevel gearboxes
Planetary Gearboxes
Hardened & Ground Helical- bevel gears & Spiral-bevels gears/gearboxes.
Rack & Pinions
Ratings:
Min 3 hp to Max 1400 hp
Splash / Forced lubrication type
Send Enquiry
With more than 1000 girth gears sold over the world CITICIC Gear is a leading supplier in the cement and mineral industry. And as member of AGMA (American Gear Manufacturers Association), we do actively take part in defining the standard for gear rating calculations and service factors.
We provide girth gears in three different designs
Fabricated steel
- forged ring
- rolled plate
Cast steel
Ductile (Nodular) cast iron
Fabricated gears became more common in the past and are constructed with forged steel gear rim materials and electro welded body structure. The rings are manufactured from a whole block of high resistance alloy steel. After the rough machining of the ring, we carry out hardening and tempering heat treatment in order to improve the mechanical characteristic and therefore its relevant performance.
Avantages of fabricated girth gears
The forged material structure excludes the risk of inclusions
Structure defects like gas holes, micro shrinkage, pin holes, hot tears, sand and slag inclusions are avoided
Hence, repair welding of the body structure and e.g. grinding of toothed areas is not required.
The fabricated manufacturing procedure excludes the need for patterns and risers
Rim material has higher hardness and higher strength than the material used for the underlying structure (i.e. web, gussets)
These features will reduce the lead time and costs. Fabricated manufacturing ensures a fast delivery.
This is especially beneficial in an emergency situation, where the existing gear rim is suffering from damage
Features
External teeth
Maximum diameter: 16000 mm
Toothed face width: 1700 mm
Maximum module: 45 by hob
Maximum module: 65 gear finishing cutter
Internal teeth
Maximum Diameter: 6500 mm
Maximum module: 25.4
Toothed face width: 400 mm
Forging material process
Forging
Final rolling
Furnace cooling
Control on production
Water quenching
Hardness testing
Rough machining
Ultrasonic testing and dimensional inspection
Final inspection certification
Standards/Certificates
UNI EN ISO
AWS
ASTM
ASME
DIN
Applications
Our girth gears are applied in the cement and minerals industries:
Various types of horizontal mills
Rotary dryers
Rotary kilns
Any other large gear ring application
Pinions
ZTIC Gear invested in significant resources and achieved many innovations with pinions. The right combination of material, hardness and finishing between pinion and gear is crucial for a long lifetime of the installed equipment. We design and manufacture pinions to match every customers need, no matter how unique the situation might be.
Pinion design
bored
solid on shaft / integral
self aligned
spur, helical or double helical
Materialization
forged alloyed steel
through hardened, case hardened or quenched and tempered
Spur, helical or double helical
carburized
induction
nitrided
Characteristics
gear cutting with hobs
the gear quality is checked by profile tester
tooth flank modification
- profile correction
- lead correction (straight/barrel)
designs /ratios according to ISO-DIN-A.G.M.A.
FEM/FEA simulation software
Standards/Certificates
UNI EN ISO
AWS
ASTM
ASME
DIN
Applications
Our pinions are applied in the cement and minerals industries:
Ball - mills
ROD - mills
Semi Autogeneous Grind (SAG)
Rotary kilns/coolers/dryers
Advantages
One Source
Original Equipment Manufacture (OEM) Technical Drawings
Gearing technical expertise for kilns and grinding mills
State of the art manufacturing facilities and quality
Global sales and service support
Rotary Kiln Girth Gears
We are leading supplier the Kiln Girth Gears for the various plants as listed below.
Sponge Iron Plants 50TPD 100TPD 300TPD350TPD,500TPD,1000TPD
Cement plants as per customer requirement
Gears for phosphate mines, Alumina plant, kaolin-bentonite
Gear Cutting Capacity:
100mm diameter to 16000mm diameter
10Module to 70Module
The Kiln girth gears are available mainly in bi-part, four parts, 8 parts or multi segments as per the requirement and suitability with the application of gear.
In the field of grinding mill components, We supply mill heads,feed inlet,grinding roller,cement kiln riding ring, casting gears, shaft block .Also we supply mill shell of welding structures and fabrications.
Quality assurance documents
The following reports are to be submitted to Quality Assurance:
a. Chemistry report
b. Physical report
c. Heat treatment documents
CITIC HMC Q/HM 973.2-2007
Specification for Steel Castings for Grinding Mills
d. Ultrasonic inspection report (before and after repairs)
e. Magnetic particle inspection report (before and after repairs)
f. Dimensional report
g. Weld repair maps
h. Weld procedures and Procedure qualification record
i. Welder qualification
j. Nondestructive testing inspector qualification
Product Parameters
Item |
Structural features |
Processing measure |
Test content |
Girth Gear |
(1)GS42CrMo4Alloy Steel (corporate proprietary standards)
HB 220~240
(2)semi-structured, Y-Spoke
(3)Helical
(4) reasonable sealing and alignment structure of alloy steel (corporate proprietary standards) |
(1) outer steel refining (R-H argon and vacuum treatment)
(2) proprietary cold mold hanging sand technology to ensure the casting, the teeth dense
(3) normalizing (proprietary technology) to ensure that the tooth surface hardness
After
(4)rough hobbing, release time, repair the joint surface, then fine roll
(5) proprietary homemade hob fine hobbing |
(1)castings mechanical properties and chemical composition (internal standard)
(2) roughing after sonic testing
(3)semi-finishing, finishing after ultrasonic testing and magnetic particle inspection
(4) tooth surface magnetic particle inspection, hardness test
(5)tooth tolerance check
(6) the factory assembly load test to check the accuracy of the size of gear |
gear manufacture process
| No. |
process |
processing
measure |
processing
equipment |
program of tests |
inspection equipment |
1 |
prepare |
1. Material: high quality cast steel
2. Formulate reasonable casting process and ensure casting quality by means of computer simulation of solidification
3. Formulate reasonable smelting process to ensure the chemical composition of casting
4. Formulate reasonable heat treatment process to ensure
Verify the mechanical properties of the casting
|
|
|
|
2 |
modelling |
1. Strictly control the quality of type (core) sand, ensure the strength and control of water
2. Sand tamping, inclined surface polishing, paint brush twice
3. Place the pouring riser and cold iron according to the process requirements
4. Clean and bake as required
cavity
|
sand mixer |
Check the quality of type (core) sand and surface sand
2. Check the cavity size
Check the baking time
|
|
3 |
Smelting casting |
1. Choose low S.P pig iron, select scrap steel, auxiliary materials and alloy of baking furnace according to process
2. According to special process smelting, make steel
S.P hazardous elements meet internal control standards
3. The finished molten steel is treated with argon blowing in the ladle and R-H vacuum circulation degassing to make the molten steel composition uniform, harmful oxygen (H, O) reduction, uniform temperature, increase the fluidity of molten steel, so as to ensure good liquid replenishing of the casting and prevent the casting from porosity and other defects
Strictly control casting temperature and casting speed according to the provisions
-
|
50 t furnace
R-h vacuum circulation degassing equipment for ladle argon blowing device
|
1. Furnace materials must meet the technological requirements
2. Control feeding temperature, feeding quantity, pure boiling time, steel temperature
3. The direct reading spectrometer is used to quickly detect the chemical composition in front of the furnace to ensure that the equipment is in the best state during melting and the chemical composition of the finished product meets the requirements during pouring
4. Check the parameters of argon blowing and R-H vacuum treatment
5. Check the starting temperature and
Pouring time
|
Direct reading spectrometer
The physical and chemical equipment
|
4 |
Cleaning and heat treatment |
1. The internal heat preservation time of casting mold shall not be less than the process requirements
2. Sand falling, shot blasting, cutting and pouring risers meet the technological requirements
3. Strictly carry out the blank heat treatment
To ensure the uniformity of furnace temperature and refine the original structure of casting
|
50t
Inert falling sand machine and
8.5 ×12m
Heat treatment furnace
|
1. Check the furnace temperature record
2. The sample is heat-treated with the casting in the same furnace, and the mechanical properties are sent to be checked immediately
3. Check the surface quality of the blank
Quantity, geometric dimension and machining allowance
|
The physical and chemical equipment |
5 |
rough machining |
1. Reserve allowance for rough machining according to technological provisions
Artificial aging treatment
|
Vertical lathe
8.5 ×12m
Heat treatment furnace
|
Check the size
Visual inspection for defects ultrasonic inspection
|
Ultrasonic
Testing |
The technical requirements of a large CITICIC Gear ring:
1) is pretreated before normalizing surface hardening treatment, the hardness should HB210 ~ 250; mechanical performance are the ultimate strength Rb \ 690MPa, yield stress Rs \ 490MPa, elongation D5 \ 11%, reduction of area W \ 25% , impact toughness Ak \ 30J; teeth induction hardened, hardness HRC50 ~ 55; effective hardened layer depth \ 3 ~ 5mm.
2) overall ultrasonic flaw detection, internal quality should meet two requirements GB7233-87 standard requirements; tooth and fillet magnetic particle inspection, quality should meet two requirements GB/T9444-88 standards.
3) Note the casting is not rounded R5 ~ R10.
4) Tooth chamfer at both ends and 1 45b.5) by two and a half ring gear tooth width of each ring coupling along the edge of a whole ring made with high strength bolts, combined with the tooth surface must be at the bottom center.
2 large ring gear manufacturing process
2.1 of rough
Steel casting blank is provided by CITIC Heavy Machinery Co., Ltd. Heavy Forging plant, run by GB11352-89 standard specifies requirements for modeling according to the casting process, smelting, casting, hit boxes, cleaning, dressing castings;. During inspection and acceptance by the drawings and Technical requirements for steel blank
Checks, according JB/T6402-92 standards issued after acceptance
Down procedure.
2.2 roughing
Crossed by drawing and stay out allowance, alignment, connection, processing both inside and outside the circle, combining face milling, drilling and other processes.
2.3 Exploration injury
Overall ultrasonic flaw detection, internal quality should meet the two requirements of GB7233-87 standards.
2.4 normalizing pretreatment
Semi-ring pairs normalizing and tempering treatment, provide a good organization for subsequent surface hardening; press drawings deformation of the half ring gear inspection after heat treatment.
2.5 Machining
First two and a half ring is made with high strength bolts connecting the ring as a whole, the overall process by drawing a circle Quannei Wai teeth and upper and lower end, and then drawing and machining milling process requirements.
2.6 Elimination of processing stress
The overall ring annealed to eliminate stress.
2.7 overall ring surface hardening
IF along the alveolar tooth surface induction hardening, hardness HRC50 ~ 55, effective hardened layer depth \ 3 ~ 5mm.
2.8 Final inspection
First, the detection frequency quenching, the hardness after tempering ring gear cogging meets the requirements of the drawings; secondly, to detect whether the maximum outer diameter larger size D6944 as the deformation \ 3mm, the mechanical correction required until qualified; Thirdly, tooth and fillet magnetic particle inspection, quality should meet two requirements GB/T9444-88 standard requirements; Finally, according to the drawings and technical requirements for final inspection.
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