China Large Diameter Girth Gear for Rotary Kilns and Grinding Mills with Great quality

Product Description

CITICIC is the casting & forging center in central-south China, possessing 50t electric powered arc furnace, 60t LF ladle refining furnace, and 60t VD/VOD refining furnace, etc. We can pour 350t liquid metal 1 time and yields much more than 200,000t of higher good quality liquid steel and can make the higher quality metal of much more than 260 metal grades such as carbon steel, structural alloy steel and the structural steel, refractory steel and stainless metal of special need. The maximum fat of casting, grey casting, graphite cast iron and non-ferrous casting is 200t, 30t, 20t and 205t separately.

 

Characteristics:

Module Assortment: ten Module to 70 Module.

Diameter: Min 800mm to16000 mm.

Bodyweight: Max one hundred twenty MT one piece.

Three diverse designs: Fabricated steel – forged ring – rolled plate

Standards / Certificates: • UNI EN ISO • AWS • ASTM • ASME • DIN

 

Positive aspects:

– Goods with Customers’ Designs

– Robust Machining & Warmth Treatment method Capabilities

– Stringent High quality Management

– Prompt Shipping

– Experience in Cooperation with Fortune five hundred Organizations

 

Method:

Forging / Casting

Normalizing & Tempering-Evidence Machining

Quenching & Tempering

End Machining (Tooth Grinding)

 

We can offer you you in a variety of approach situations options for Numerous Conclude Markets and Apps

–Mining

–Metallurgy

–Electricity Generation

–Sugar

–Cement Plant

–Port Machinery

–Oil and all-natural

–Papermaking

–OEM equipment situation

–Common Industrial

 

Requirements Of Equipment:

No.

Product

Description

one

Diameter

≤15m

2

Module

≤45

three

Materials

Forged Alloy Steel, Solid Carbon Steel, Forged Alloy Steel, Forged Carbon Metal

4

Construction From

Integrated, 50 percent to Fifty percent, Four Pieces and More Items

     

5

Warmth Treatment

Quenching & Tempering, Normalizing & Tempering, Carburizing & Quenching & Tempering

     

6

Tooth Sort

Annular Equipment, Outer Gear Ring

7

Normal

ISO, EN, DIN, AISI, ASTM, JIS, IS, GB

 

Inspection And Test Outline Of Girth Gear:

No.

Item

Inspection Area

Acceptance Requirements

Inspection Stage

Certificates

one

Chemical 
Composition

Sample

Materials Need

When Smelting
Right after Warmth Therapy

Chemical Composition 
Report

two

Mechanical
Qualities

Sample (Check Bar on the Gear Human body)

Specialized Prerequisite

Right after Heat Treatment

Mechanical Properties 
Report

three

Heat 
Therapy

Total Entire body

Manufacturing Regular

During Heat Treatment method

Heat Treatment method Report
Curves of Heat 
Treatment

four

Hardness 
Check

Tooth Surface, 3 Factors For each 90°

Complex Requirement

Right after Heat Therapy

Hardness Teat Report

Soon after Semi Finish 
Machining

         

5

Dimension 
Inspection

Total Physique

Drawing

Right after Semi End

Machining

Dimension Inspection 
Report

Complete Machining

         

6

Magnetic Power Take a look at (MT)

Tooth Area

Agreed Regular

Right after Finish Gear 
Hobbing

MT Report

7

UT

Spokes Parts

Agreed Common

After Rough Machining

UT Report

After Welded

         

After Semi Finish 
Machining

         

8

PT

Defect Region

No Defect Indicated

Following Digging
Soon after Welded

PT Record

9

Mark Inspection

Whole Physique

Producing Standard

Closing Inspection

Photos

10

Appearance Inspection

Whole Human body

CIC’s Need

Ahead of Packing (Final Inspection)

 

11

Anti-rust 
Inspection

Entire Entire body

Agreed Anti-rust Agent

Before Packing

Pictures

twelve

Packing 
Inspection

Whole Body

Agreed Packing Form

In the course of Packing

Images

 

Facilities For Production Gear Ring:

No

Item

Description

one

Smelting & Casting Ability

40t, 50t, 80t Sequence AC Electrical Arc Furnace
2×150t, 60t LF Ladle Refining Furnace
150t, 60t Series VD / VOD Furnace
20×18m Huge Pouring Facility

We can pour 900t refining liquid steel 1 time, and obtain vacuum poured 600t steel ingots.

We can generate the high good quality metal of more than 260 steel grades as carbon metal, structural alloy steel and the structural metal, refractory steel and stainless steel of particular requirement. 

The optimum fat of casting metal, grey casting, graphite cast iron and non-ferrous casting is 600t, 200t, 150t and 20t separately.

two

Forging Capability

The only 1 in the word, the most technologically advanced and the largest 
specification18500t Oil Push, geared up with 750t.m forging operation equipment
8400t H2o Push
3150t H2o Press
1600t Drinking water Push
Φ5m Higher Precision Ring Mill (Germany)
Φ12m Higher Precision Ring Mil
We can roll rings of diverse sections of carbon metal, alloy steel, substantial temperature alloy steel and non-ferrous alloys these kinds of as copper alloy, aluminum alloy and titanium alloy. 
Max. Diameter of rolled ring will be 12m.

three

Heat Treatment Functionality

9×9×15m, 8×8×12m, 6×6×15m, 15×16×6.5m, 16×20×6m, 7×7×17m Series Warmth CZPT and Warmth Therapy Furnaces

φ2.0×30m, φ3.0×5.0m Sequence Warmth Treatment method Furnaces
φ5.0×2.5m, φ3.2×1.5m, φ3.0×5.0m, φ2.0×5m Collection Carburizing Furnaces &
Nitriding Furnaces & Quenching Bathes
φ2.0×30m Well Kind CNC Electrical Furnaces
Φ3.0×5.0M Horizontal Fuel Temperature-differential Furnace
Double-frequency and Double-place Quenching Lathe of Pinion Shaft

four

Machining Capability

1. ≥5m CNC Large Obligation Vertical Lathes

12m CNC Double-column Vertical Lathe
10m CNC Double-column Vertical Lathe
10m CNC One-column Vertical Lathe
six.3m Weighty Duty Vertical Lathe
5m CNC Heavy Obligation Vertical Lathe

 

2. ≥5m Vertical Equipment Hobbing Devices
15m CNC Vertical Gear Hobbing Equipment
10m Gear Hobbing Machine
8m Equipment Hobbing Machine
5m Equipment Hobbing Equipment
3m Equipment Hobbing Machining

 

three. Imported Higher-precision Gear Grinding Devices
.8m~3.5m CNC Molding Equipment Grinding Machines

 

4. Massive Boring & Milling Machines
220 CNC Ground-mounted Boring & Milling Device
200 CNC Floor-mounted Uninteresting & Milling Device
160 CNC Flooring-mounted Unexciting & Milling Device

 

US $200-8,000
/ Piece
|
1 Piece

(Min. Order)

###

Application: Industry
Hardness: According to Customer′s Requirement
Gear Position: External Gear
Manufacturing Method: Cast Gear
Toothed Portion Shape: Spur Gear
Material: Steel

###

Customization:

###

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

###

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

         

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

         

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

###

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 (Germany)
Φ12m High Precision Ring Mil
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

 

3. Imported High-precision Gear Grinding Machines
0.8m~3.5m CNC Molding Gear Grinding Machines

 

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

US $200-8,000
/ Piece
|
1 Piece

(Min. Order)

###

Application: Industry
Hardness: According to Customer′s Requirement
Gear Position: External Gear
Manufacturing Method: Cast Gear
Toothed Portion Shape: Spur Gear
Material: Steel

###

Customization:

###

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

###

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

         

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

         

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

###

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 (Germany)
Φ12m High Precision Ring Mil
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

 

3. Imported High-precision Gear Grinding Machines
0.8m~3.5m CNC Molding Gear Grinding Machines

 

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

How to Design a Forging Spur Gear

Before you start designing your own spur gear, you need to understand its main components. Among them are Forging, Keyway, Spline, Set screw and other types. Understanding the differences between these types of spur gears is essential for making an informed decision. To learn more, keep reading. Also, don’t hesitate to contact me for assistance! Listed below are some helpful tips and tricks to design a spur gear. Hopefully, they will help you design the spur gear of your dreams.
Gear

Forging spur gears

Forging spur gears is one of the most important processes of automotive transmission components. The manufacturing process is complex and involves several steps, such as blank spheroidizing, hot forging, annealing, phosphating, and saponification. The material used for spur gears is typically 20CrMnTi. The process is completed by applying a continuous through extrusion forming method with dies designed for the sizing band length L and Splitting angle thickness T.
The process of forging spur gears can also use polyacetal (POM), a strong plastic commonly used for the manufacture of gears. This material is easy to mold and shape, and after hardening, it is extremely stiff and abrasion resistant. A number of metals and alloys are used for spur gears, including forged steel, stainless steel, and aluminum. Listed below are the different types of materials used in gear manufacturing and their advantages and disadvantages.
A spur gear’s tooth size is measured in modules, or m. Each number represents the number of teeth in the gear. As the number of teeth increases, so does its size. In general, the higher the number of teeth, the larger the module is. A high module gear has a large pressure angle. It’s also important to remember that spur gears must have the same module as the gears they are used to drive.

Set screw spur gears

A modern industry cannot function without set screw spur gears. These gears are highly efficient and are widely used in a variety of applications. Their design involves the calculation of speed and torque, which are both critical factors. The MEP model, for instance, considers the changing rigidity of a tooth pair along its path. The results are used to determine the type of spur gear required. Listed below are some tips for choosing a spur gear:
Type A. This type of gear does not have a hub. The gear itself is flat with a small hole in the middle. Set screw gears are most commonly used for lightweight applications without loads. The metal thickness can range from 0.25 mm to 3 mm. Set screw gears are also used for large machines that need to be strong and durable. This article provides an introduction to the different types of spur gears and how they differ from one another.
Pin Hub. Pin hub spur gears use a set screw to secure the pin. These gears are often connected to a shaft by dowel, spring, or roll pins. The pin is drilled to the precise diameter to fit inside the gear, so that it does not come loose. Pin hub spur gears have high tolerances, as the hole is not large enough to completely grip the shaft. This type of gear is generally the most expensive of the three.
Gear

Keyway spur gears

In today’s modern industry, spur gear transmissions are widely used to transfer power. These types of transmissions provide excellent efficiency but can be susceptible to power losses. These losses must be estimated during the design process. A key component of this analysis is the calculation of the contact area (2b) of the gear pair. However, this value is not necessarily applicable to every spur gear. Here are some examples of how to calculate this area. (See Figure 2)
Spur gears are characterized by having teeth parallel to the shafts and axis, and a pitch line velocity of up to 25 m/s is considered high. In addition, they are more efficient than helical gears of the same size. Unlike helical gears, spur gears are generally considered positive gears. They are often used for applications in which noise control is not an issue. The symmetry of the spur gear makes them especially suitable for applications where a constant speed is required.
Besides using a helical spur gear for the transmission, the gear can also have a standard tooth shape. Unlike helical gears, spur gears with an involute tooth form have thick roots, which prevents wear from the teeth. These gears are easily made with conventional production tools. The involute shape is an ideal choice for small-scale production and is one of the most popular types of spur gears.

Spline spur gears

When considering the types of spur gears that are used, it’s important to note the differences between the two. A spur gear, also called an involute gear, generates torque and regulates speed. It’s most common in car engines, but is also used in everyday appliances. However, one of the most significant drawbacks of spur gears is their noise. Because spur gears mesh only one tooth at a time, they create a high amount of stress and noise, making them unsuitable for everyday use.
The contact stress distribution chart represents the flank area of each gear tooth and the distance in both the axial and profile direction. A high contact area is located toward the center of the gear, which is caused by the micro-geometry of the gear. A positive l value indicates that there is no misalignment of the spline teeth on the interface with the helix hand. The opposite is true for negative l values.
Using an upper bound technique, Abdul and Dean studied the forging of spur gear forms. They assumed that the tooth profile would be a straight line. They also examined the non-dimensional forging pressure of a spline. Spline spur gears are commonly used in motors, gearboxes, and drills. The strength of spur gears and splines is primarily dependent on their radii and tooth diameter.
SUS303 and SUS304 stainless steel spur gears

Stainless steel spur gears are manufactured using different techniques, which depend on the material and the application. The most common process used in manufacturing them is cutting. Other processes involve rolling, casting, and forging. In addition, plastic spur gears are produced by injection molding, depending on the quantity of production required. SUS303 and SUS304 stainless steel spur gears can be made using a variety of materials, including structural carbon steel S45C, gray cast iron FC200, nonferrous metal C3604, engineering plastic MC901, and stainless steel.
The differences between 304 and 303 stainless steel spur gears lie in their composition. The two types of stainless steel share a common design, but have varying chemical compositions. China and Japan use the letters SUS304 and SUS303, which refer to their varying degrees of composition. As with most types of stainless steel, the two different grades are made to be used in industrial applications, such as planetary gears and spur gears.
Gear

Stainless steel spur gears

There are several things to look for in a stainless steel spur gear, including the diametral pitch, the number of teeth per unit diameter, and the angular velocity of the teeth. All of these aspects are critical to the performance of a spur gear, and the proper dimensional measurements are essential to the design and functionality of a spur gear. Those in the industry should be familiar with the terms used to describe spur gear parts, both to ensure clarity in production and in purchase orders.
A spur gear is a type of precision cylindrical gear with parallel teeth arranged in a rim. It is used in various applications, such as outboard motors, winches, construction equipment, lawn and garden equipment, turbine drives, pumps, centrifuges, and a variety of other machines. A spur gear is typically made from stainless steel and has a high level of durability. It is the most commonly used type of gear.
Stainless steel spur gears can come in many different shapes and sizes. Stainless steel spur gears are generally made of SUS304 or SUS303 stainless steel, which are used for their higher machinability. These gears are then heat-treated with nitriding or tooth surface induction. Unlike conventional gears, which need tooth grinding after heat-treating, stainless steel spur gears have a low wear rate and high machinability.

China Large Diameter Girth Gear for Rotary Kilns and Grinding Mills     with Great qualityChina Large Diameter Girth Gear for Rotary Kilns and Grinding Mills     with Great quality
editor by czh 2023-01-13

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