Rotating gear ring for ball mill
| Product Name | Steel girth spur gear |
| Weight | Max 120 MT single piece |
| Applications | industries |
| Module Range | 10 Module to 70 Module. |
| Diameter | Min 100 mm to16000 mm. |
| Weight | Max 120 MT single piece. |
| Gear Cutting Capacity | 100mm diameter to 16000mm diameter,10Module to 70Module |
| 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 |
Rotating gear ring for ball mill 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.
CITIC IC 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
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 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
CITICIC 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
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
Ring gear for cement ball mill
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
1 5
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
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 |
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.
