Product Description
Product Description
Factory price large Cast Steel, Iron Kiln Girth Gear for ball mill
Casting & forging ability
CITICHL is the casting & forging center in central-south China, possessing 50t electric arc furnace, 60t LF ladle refining furnace, and 60t VD/VOD refining furnace, etc. We can pour 350t liquid steel 1 time and yields more than 200,000t of high quality liquid steel and can produce the high quality steel of more than 260 steel grades such as carbon steel, structural alloy steel and the structural steel, refractory steel and stainless steel of special requirement. The maximum weight of casting, gray casting, graphite cast iron and non-ferrous casting is 200t, 30t, 20t and 205t separately.
The company is the forging center in central-south China. It is very powerful in forging. The single free forging is 100t(max weight). We can roll rings of different sections of carbon steel, alloy steel, high temperature alloy and non-ferrous alloys such as copper alloy, aluminum alloy and titanium alloy. The maximum diameter is 5.5m and single piece of the forging weighs 10t. We have 8400t, 3150t, 1600t, water press and RAW 200/160-5000/750 large-size ring mill of high precision in Asia made in WAGNER, Germany.
Our girth gears Features
Module Range: 10 Module to 70 Module.
Diameter : Min 800mm to16000 mm.
Weight : Max 120 MT single piece.
Three different designs: Fabricated steel – forged ring – rolled plate
Standards/Certificates :• CHINAMFG EN ISO • AWS • ASTM • ASME • DIN
Girth gear cutting machines
Φ16m CNC hobbing Machine
Φ12m Gear cutting machine (Switzerland)
Φ10m hobbing machine (Germany)
Φ4m CNC high speed hobbing machine (Germany)
Φ1.6m Horizontal CNC hobbing machine (Germany)
Φ5m CNC profile gear grinding machine (Germany)
Φ2.8m CNC Profile gear grinding machine (Germany)
Φ1.25m CNC Profile gear grinding machine (Germany)
Φ1m CNC Profile gear grinding machine (Germany)
Specifications of Gear :
| No. | Item | Description | |
| 1 | Diameter | ≤15m | |
| 2 | Module | ≤45 | |
| 3 | Material | Cast Alloy Steel, Cast Carbon Steel, Forged Alloy Steel, Forged Carbon Steel | |
| 4 | Structure From | Integrated, Half to Half, Four Pieces and More Pieces | |
| 5 | Heat Treatment | Quenching & Tempering, Normalizing & Tempering, Carburizing & Quenching & Tempering | |
| 6 | Tooth Form | Annular Gear, Outer Gear Ring | |
| 7 | Standard | ISO, EN, DIN, AISI, ASTM, JIS, IS, GB |
Inspection and Test Outline of Girth Gear:
| No. | Item | Inspection Area | Acceptance Criteria | Inspection Stage | Certificates |
| 1 | Chemical Composition |
Sample | Material Requirement | When Smelting After Heat Treatment |
Chemical Composition Report |
| 2 | Mechanical Properties |
Sample(Test Bar on the Gear Body) | Technical Requirement | After Heat Treatment | Mechanical Properties Report |
| 3 | Heat Treatment |
Whole Body | Manufacturing Standard | During Heat Treatment | Heat Treatment Report Curves of Heat Treatment |
| 4 | Hardness Test |
Tooth Surface, 3 Points Per 90° | Technical Requirement | After Heat Treatment | Hardness Teat Report |
| After Semi Finish Machining |
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| 5 | Dimension Inspection |
Whole Body | Drawing | After Semi Finish Machining |
Dimension Inspection Report |
| Finish Machining | |||||
| 6 | Magnetic Power Test (MT) | Tooth Surface | Agreed Standard | After Finish Gear Hobbing |
MT Report |
| 7 | UT | Spokes Parts | Agreed Standard | After Rough Machining | UT Report |
| After Welded | |||||
| After Semi Finish Machining |
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| 8 | PT | Defect Area | No Defect Indicated | After Digging After Welded |
PT Record |
| 9 | Mark Inspection | Whole Body | Manufacturing Standard | Final Inspection | Pictures |
| 10 | Appearance Inspection |
Whole Body | CIC’s Requirement | Before Packing (Final Inspection) |
|
| 11 | Anti-rust Inspection |
Whole Body | Agreed Anti-rust Agent | Before Packing | Pictures |
| 12 | Packing Inspection |
Whole Body | Agreed Packing Form | During Packing | Pictures |
Facilities For Manufacturing Gear ring:
| No. | Item | Description |
| 1 | Smelting & Casting Capability | 40t ,50t, 80t Series AC Electric Arc Furnace 2×150t, 60t LF Ladle Refining Furnace 150t, 60t Series VD/VOD Furnace 20×18m Large Pouring Facility We can pour 900t refining liquid steel one time, and achieve vacuum poured 600t steel ingots. We can produce the high quality steel of more than 260 steel grades as carbon steel,structural alloy steel and the structural steel, refractory steel and stainless steel of special requirement. The maximum weight of casting steel, gray casting, graphite cast iron and non-ferrous casting is 600t, 200t, 150t and 20t separately. |
| 2 | Forging Capability | The only one in the word, the most technologically advanced and the largest specification18500t Oil Press, equipped with 750t.m forging operation machine 8400t Water Press 3150t Water Press 1600t Water Press Φ5m High Precision Ring Mill ( WAGNER,Germany) Φ12m High Precision Ring Mill We can roll rings of different sections of carbon steel, alloy steel, high temperature alloy steel and non-ferrous alloys such as copper alloy, aluminum alloy and titanium alloy. Max. Diameter of rolled ring will be 12m. |
| 3 | Heat Treatment Capability | 9×9×15m,8×8×12m,6×6×15m,15×16×6.5m,16×20×6m ,7×7×17m Series Heat Furnace and Heat Treatment Furnaces φ2.0×30m,φ3.0×5.0m Series Heat Treatment Furnaces φ5.0×2.5m,φ3.2×1.5m,φ3.0×5.0m,φ2.0×5m Series Carburizing Furnaces & Nitriding Furnaces & Quenching Bathes φ2.0×30m Well Type CNC Electrical Furnaces Φ3.0×5.0M Horizontal Gas Temperature-differential Furnace Double-frequency and Double-position Quenching Lathe of Pinion Shaft |
| 4 | Machining Capability | 1. ≥5m CNC Heavy Duty Vertical Lathes 12m CNC Double-column Vertical Lathe 10m CNC Double-column Vertical Lathe 10m CNC Single-column Vertical Lathe 6.3m Heavy Duty Vertical Lathe 5m CNC Heavy Duty Vertical Lathe |
| 2. ≥5m Vertical Gear Hobbing Machines 15m CNC Vertical Gear Hobbing Machine 10m Gear Hobbing Machine 8m Gear Hobbing Machine 5m Gear Hobbing Machine 3m Gear Hobbing Machining |
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| 3. Imported High-precision Gear Grinding Machines 0.8m~3.5m CNC Molding Gear Grinding Machines |
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| 4. Large Boring & Milling Machines 220 CNC Floor-mounted Boring & Milling Machine 200 CNC Floor-mounted Boring & Milling Machine 160 CNC Floor-mounted Boring & Milling Machine |
| Application: | Industry |
|---|---|
| Hardness: | According to Customer′s Requirement |
| Gear Position: | External Gear |
| Manufacturing Method: | Cast Gear |
| Toothed Portion Shape: | Spur Gear |
| Material: | Steel |
| Customization: |
Available
| Customized Request |
|---|
What is the lifespan of a typical bevel gear?
The lifespan of a typical bevel gear can vary depending on several factors, including the quality of the gear, the operating conditions, maintenance practices, and the specific application. Here’s a detailed explanation:
Bevel gears, like any mechanical component, have a finite lifespan. The lifespan of a bevel gear is influenced by the following factors:
- Quality of the Gear: The quality of the gear itself is a significant factor in determining its lifespan. Bevel gears manufactured using high-quality materials and precise manufacturing processes tend to have longer lifespans. Gears made from durable materials and manufactured with tight tolerances and accurate tooth profiles are more resistant to wear and fatigue, resulting in extended lifespans.
- Operating Conditions: The operating conditions under which the bevel gear operates greatly affect its lifespan. Factors such as torque levels, rotational speed, temperature, and shock loads can impact the wear and fatigue characteristics of the gear. Gears subjected to high torque, high-speed rotation, excessive heat, or frequent heavy loads may experience accelerated wear and reduced lifespan compared to gears operating under milder conditions.
- Maintenance Practices: Proper maintenance practices can significantly extend the lifespan of a bevel gear. Regular inspection, lubrication, and preventive maintenance help identify and address potential issues before they escalate. Adequate lubrication, cleanliness, and alignment contribute to reducing wear, minimizing the risk of damage, and prolonging the gear’s lifespan. Neglecting maintenance or improper maintenance practices can lead to premature wear, failure, and reduced lifespan.
- Application Specifics: The specific application in which the bevel gear is used plays a vital role in determining its lifespan. Different applications impose varying loads, speeds, and operating conditions on the gear. Gears used in heavy-duty industrial applications, such as mining or heavy machinery, may experience more significant wear and have shorter lifespans compared to gears used in lighter-duty applications.
- Load Distribution: Proper load distribution among the gear teeth is critical for ensuring longevity. Evenly distributed loads help prevent localized wear and ensure that no individual teeth are subjected to excessive stress. Factors such as gear design, tooth profile, and accurate alignment influence load distribution and can impact the gear’s lifespan.
Due to the complex interplay of these factors, it is challenging to provide a specific lifespan for a typical bevel gear. However, with proper design, high-quality manufacturing, suitable operating conditions, regular maintenance, and appropriate load distribution, bevel gears can have a lifespan ranging from several thousand to tens of thousands of operating hours.
It is important to note that monitoring the gear’s condition, including wear patterns, tooth damage, and any signs of failure, is crucial for ensuring safe and reliable operation. When signs of wear or damage become significant or when the gear no longer meets the required performance criteria, replacement or refurbishment should be considered to maintain the overall system’s integrity and performance.
Can bevel gears be used in automotive applications?
Yes, bevel gears can be used in automotive applications due to their unique characteristics and ability to transmit power between intersecting shafts at different angles. Here’s a detailed explanation:
Bevel gears are commonly found in various automotive systems and components, offering several advantages for specific applications. Here are some key automotive applications where bevel gears are utilized:
- Differential: One of the primary applications of bevel gears in automotive systems is in the differential mechanism. The differential is responsible for distributing torque between the drive wheels while allowing them to rotate at different speeds, especially during cornering. Bevel gears, specifically hypoid gears, are used in the differential to transfer power from the driveshaft to the wheel axles at right angles. The compact size and high torque transmission capability of bevel gears make them suitable for this critical drivetrain component.
- Power Transfer: Bevel gears are utilized in automotive power transfer systems, such as transfer cases and drivelines. Transfer cases, commonly found in four-wheel drive (4WD) and all-wheel drive (AWD) vehicles, transfer power from the transmission to the front and rear axles. Bevel gears enable the necessary change in direction and torque transmission between the input and output shafts of the transfer case. Similarly, bevel gears can be used in drivelines to transfer power between differentials or between the transmission and the axles.
- Steering Systems: Bevel gears play a role in automotive steering systems, particularly in rack-and-pinion steering mechanisms. In these systems, bevel gears are used to convert the rotational motion of the steering wheel into the linear motion required for steering. Bevel gears help change the direction of motion, enabling the driver to control the vehicle’s steering angle. The compact size and precise motion transmission characteristics of bevel gears make them suitable for these steering applications.
- Auxiliary Systems: Bevel gears find application in various auxiliary automotive systems. For example, they can be used in engine timing systems to drive camshafts and synchronize valve operation. Bevel gears can also be employed in automotive differentials with limited-slip or locking capabilities, enhancing traction and vehicle stability in challenging road conditions. Additionally, they can be found in power seat adjusters, sunroof mechanisms, and other vehicle systems where torque transmission at different angles is required.
Bevel gears used in automotive applications are typically designed to withstand high loads, operate with minimal noise and vibration, and provide reliable power transmission. They are often manufactured from durable materials, such as alloy steels, and undergo heat treatment processes to enhance their strength and wear resistance.
It is important to note that the specific design and selection of bevel gears for automotive applications depend on factors such as torque requirements, space limitations, operating conditions, and cost considerations. Gear engineers and automotive manufacturers carefully consider these factors to ensure optimal performance, efficiency, and reliability in automotive systems.
In summary, bevel gears are extensively used in automotive applications, including differentials, power transfer systems, steering mechanisms, and auxiliary systems. Their ability to transmit power at varying angles, compact size, and robust construction make them well-suited for the demanding requirements of the automotive industry.
How do you calculate the gear ratio of a bevel gear?
Calculating the gear ratio of a bevel gear involves determining the ratio between the number of teeth on the driving gear (pinion) and the driven gear (crown gear). Here’s a detailed explanation of how to calculate the gear ratio of a bevel gear:
The gear ratio is determined by the relationship between the number of teeth on the pinion and the crown gear. The gear ratio is defined as the ratio of the number of teeth on the driven gear (crown gear) to the number of teeth on the driving gear (pinion). It can be calculated using the following formula:
Gear Ratio = Number of Teeth on Crown Gear / Number of Teeth on Pinion Gear
For example, let’s consider a bevel gear system with a crown gear that has 40 teeth and a pinion gear with 10 teeth. The gear ratio can be calculated as follows:
Gear Ratio = 40 / 10 = 4
In this example, the gear ratio is 4:1, which means that for every four revolutions of the driving gear (pinion), the driven gear (crown gear) completes one revolution.
It’s important to note that the gear ratio can also be expressed as a decimal or a percentage. For the example above, the gear ratio can be expressed as 4 or 400%.
Calculating the gear ratio is essential for understanding the speed relationship and torque transmission between the driving and driven gears in a bevel gear system. The gear ratio determines the relative rotational speed and torque amplification or reduction between the gears.
It’s worth mentioning that the gear ratio calculation assumes ideal geometries and does not consider factors such as backlash, efficiency losses, or any other system-specific considerations. In practical applications, it’s advisable to consider these factors and consult gear manufacturers or engineers for more accurate calculations and gear selection.
In summary, the gear ratio of a bevel gear is determined by dividing the number of teeth on the crown gear by the number of teeth on the pinion gear. The gear ratio defines the speed and torque relationship between the driving and driven gears in a bevel gear system.
editor by CX 2023-09-13