China wholesaler Ball Mill Casting Rotary Helical Big Girth Gear Custom Rotary Dryer CZPT High Quality Large Ring Gear gear cycle

Product Description

 Cement industrial Rotary kiln tyre girth gear casting iron gear ring large big ball mill spur gear wheel    

Product Description

 

Process: 
Forging/Casting
Normalizing&Tempering-Proof Machinnig
Quenching&Tempering
Finish Machining(Teeth Grinding)

We can offer you in various process conditions Solutions for Many End Markets and Applications
–Mining
–Metallurgy
–Power Generation
–Cement Plant
–Port Machinery
–Oil and natural
–Paper making
–OEM gear case
–General Industrial

Specification Machining Scope
Size OD Max 16m
One Piece of Gear: OD Max 13m
Assemble Gear: According to drawings
Hobbing Modulus 10-60
Milling Modulus Up to 120
Spiral Modulus 1-15
Accuracy Grade Milling: 6 grade
Hobbing: 8 grade
Material Alloy steel: 42CrMo4, 34CrNiMo6 etc.
Carbon steel: C45E, 1030
Carburizing steel
Quenched and tempered steel
Heat treatment Quenching & Tempering, Surface Quenching
Teeth Profile Spur, Helical, Herringbone, Crown, Spiral, Worm and shaft

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
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

 Testing Process:
· QA DOC: Chemical Composition Report, Mechanical Properties Report, UT Report, Heat Treatment Report, Dimensions Check Report
·  UT test: 100% ultrasonic test according to EN15718-3, SA388, Sep 1921 C/c etc.
· Heat Treatment Report: provide original copy of heat treatment curve/time table.

FAQ

 

1. What is your minimum order quantity?
   Our minimum order quantity typically ranges from 5 to 100 pieces, depending on the product and material.

2. Can you provide custom designs?
   Yes, we specialize in providing custom designs based on your specific requirements.

3. What is your production capacity?
   Our production capacity varies depending on the product and material, but we have the capability to produce millions of pieces per year.

4. What is your lead time for orders?
   Our lead time for orders is typically 4-6 weeks for production and delivery.

5. Do you offer quality control and testing?
   Yes, we have strict quality control measures in place and offer testing services, including non-destructive testing, to ensure the quality of our products.
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Application: Machinery, Industry
Hardness: According to Customers′ Requirements
Gear Position: Internal Gear

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Payment Method:







 

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Currency: US$
Return&refunds: You can apply for a refund up to 30 days after receipt of the products.

helical gear

How do you maintain and service a helical gear system?

Maintaining and servicing a helical gear system is essential to ensure its long-term performance, reliability, and longevity. Proper maintenance practices help identify and address potential issues before they lead to gear failure or reduced efficiency. Here’s a detailed explanation of how to maintain and service a helical gear system:

  1. Regular Inspection: Perform regular visual inspections of the helical gear system to check for any signs of wear, damage, or misalignment. Inspect the gear teeth, shafts, bearings, and lubrication system for any abnormalities. Look for indications such as pitting, chipping, excessive tooth wear, or unusual noise or vibration during operation.
  2. Lubrication Maintenance: Ensure proper lubrication of the helical gears as per the manufacturer’s recommendations. Monitor lubricant levels, quality, and contamination. Periodically check and replenish or replace the lubricant as necessary. Follow the recommended lubrication intervals and use the appropriate lubricant type and viscosity for the operating conditions.
  3. Gear Cleaning: Keep the gear system clean and free from debris or contaminants. Regularly remove any accumulated dirt, dust, or foreign particles that may affect the gear performance. Use appropriate cleaning methods such as brushing, wiping, or compressed air to maintain a clean gear environment.
  4. Alignment Check: Misalignment can lead to premature gear failure and reduced efficiency. Periodically check the shaft alignment using precision alignment tools. Ensure that the shafts are properly aligned both radially and axially. If misalignment is detected, take corrective measures such as adjusting the shaft positions or using shims to reestablish proper alignment.
  5. Check Gear Meshing: Monitor the gear meshing to ensure proper tooth engagement and contact. Regularly inspect the tooth contact pattern to identify any irregularities or changes. If necessary, make adjustments to the gear position or shim thickness to achieve the desired tooth contact pattern and optimize gear performance.
  6. Bearing Maintenance: Check the condition of the bearings supporting the helical gears. Monitor for any signs of wear, damage, or inadequate lubrication. Replace worn-out or faulty bearings promptly to prevent further damage to the gear system. Follow the manufacturer’s guidelines for bearing maintenance, lubrication, and replacement.
  7. Vibration Analysis: Perform periodic vibration analysis to detect any abnormal vibration patterns that may indicate gear or bearing problems. Use vibration monitoring tools and techniques to identify the source and severity of the vibrations. If excessive vibrations are detected, investigate and rectify the underlying causes to prevent gear damage or failure.
  8. Temperature Monitoring: Monitor the temperature of the helical gear system during operation. Excessive heat can be an indication of inadequate lubrication, overloading, or other issues. Regularly measure and record the gear system’s operating temperature to identify any abnormal temperature rise and take appropriate action if necessary.
  9. Training and Documentation: Ensure that maintenance personnel are properly trained in helical gear system maintenance and servicing. Maintain detailed documentation of maintenance activities, including inspection records, lubrication schedules, and any repairs or replacements performed. This documentation helps track the gear system’s history and assists in troubleshooting and future maintenance planning.
  10. Consult with Experts: When in doubt or when dealing with complex gear systems, consult with gear manufacturers, industry experts, or experienced engineers for guidance on specific maintenance procedures or troubleshooting techniques. They can provide valuable insights and recommendations based on their expertise and experience.

By following these maintenance and servicing practices, you can ensure the optimal performance, reliability, and longevity of your helical gear system. Regular inspections, proper lubrication, alignment checks, and timely repairs or replacements are crucial for minimizing downtime, extending gear life, and maximizing the efficiency of the gear system.

helical gear

Can helical gears be used in precision manufacturing equipment?

Yes, helical gears can be used in precision manufacturing equipment, and they are often chosen for their specific advantages in such applications. Helical gears offer several features that make them suitable for precision manufacturing equipment. Here is a detailed explanation:

  • Smooth and Precise Operation: Helical gears provide smooth and precise operation due to their gradual engagement of teeth. The helical tooth profile allows for gradual contact between mating gears, resulting in reduced noise, vibration, and backlash. The smooth operation is essential in precision manufacturing equipment where precise motion control and accuracy are required.
  • High Load Capacity: Helical gears have high load-carrying capacity due to the larger contact area between the teeth compared to other gear types. This feature is beneficial in precision manufacturing equipment that may encounter heavy loads or high torque requirements. The increased load capacity ensures the gears can withstand the forces involved in precision machining or manufacturing processes.
  • Efficiency: Helical gears can achieve high efficiency levels, especially when properly designed and manufactured. The helical tooth profile allows for efficient power transmission with minimal energy losses. In precision manufacturing equipment, high efficiency is desirable to maximize the utilization of input power and minimize heat generation.
  • Compact Design: Helical gears have a compact design that allows for efficient use of space in precision manufacturing equipment. The helical gear configuration can provide a higher gear ratio in a smaller package compared to other gear types, making it suitable for equipment with limited space or complex layouts.
  • Wide Range of Applications: Helical gears are versatile and can be used in various precision manufacturing equipment. They are commonly found in gearboxes, machine tools, milling machines, lathes, robotics, printing presses, and other equipment where precise motion control and high accuracy are required.

When using helical gears in precision manufacturing equipment, it is crucial to consider factors such as gear quality, material selection, lubrication, and proper alignment. High-quality gear manufacturing processes, accurate gear tooth profiles, and precise gear alignment are essential for achieving the desired precision and performance in manufacturing equipment.

Overall, helical gears are a popular choice in precision manufacturing equipment due to their smooth operation, high load capacity, efficiency, and compact design. Their versatility and ability to deliver precise motion control make them well-suited for various applications in precision manufacturing.

helical gear

Can you explain the concept of helical gear teeth and their orientation?

The concept of helical gear teeth and their orientation is essential to understanding the design and operation of helical gears. Here’s a detailed explanation of helical gear teeth and their orientation:

A helical gear consists of teeth that are cut in a helical pattern around the gear’s circumference. Unlike spur gears, which have teeth that are perpendicular to the gear axis, helical gears have teeth that are angled or inclined with respect to the gear axis. This inclination gives the teeth a helix shape, resulting in the name “helical” gears.

The orientation of helical gear teeth is defined by two main parameters:

  1. Helix Angle: The helix angle represents the angle formed between the tooth surface and an imaginary line perpendicular to the gear axis. It determines the degree of inclination or spiral of the gear teeth. The helix angle is typically measured in degrees. Positive helix angles indicate a right-hand helix, where the teeth slope in a right-hand direction when viewed from the gear’s end. Negative helix angles represent a left-hand helix, where the teeth slope in a left-hand direction. The helix angle affects the gear’s performance characteristics, including tooth engagement, load distribution, and axial thrust.
  2. Lead Angle: The lead angle is the angle formed by the helical tooth and a plane perpendicular to the gear axis. It represents the angle of advance of the helix over one revolution of the gear. The lead angle is equal to the helix angle divided by the gear’s number of teeth. It is commonly used to define the helical gear’s size and pitch.

The helical tooth orientation offers several advantages over spur gears:

  • Smooth and Quiet Operation: The helical shape of the teeth allows for gradual engagement and disengagement during gear rotation. This results in smoother and quieter operation compared to spur gears, which often produce noise due to the sudden contact between teeth.
  • Increased Load-Carrying Capacity: The helical tooth design provides a larger contact area between meshing gears compared to spur gears. This increased contact area allows helical gears to transmit higher loads and handle greater torque without excessive wear or tooth failure.
  • Load Distribution: The helical orientation of the teeth enables load distribution along the tooth face. Multiple teeth are engaged simultaneously, distributing the load across a broader surface area. This characteristic helps minimize stress concentrations and increases the gear’s durability.
  • Axial Thrust Load: The helical tooth engagement introduces axial forces and thrust loads along the gear axis. These forces must be properly supported and managed in the gear system design to ensure smooth operation and prevent excessive wear or failure.

The design and manufacturing of helical gears require specialized cutting tools and machining processes. The helical teeth are typically generated using gear hobbing or gear shaping methods. The tooth profile is carefully designed to ensure proper meshing and minimize noise, vibration, and wear.

In summary, helical gear teeth have a helical or spiral shape, which distinguishes them from the perpendicular teeth of spur gears. The orientation of helical gear teeth is defined by the helix angle and lead angle. Helical gears offer advantages such as smooth operation, increased load-carrying capacity, load distribution, and axial thrust load. These characteristics make helical gears suitable for applications that require efficient power transmission, precise motion control, and reduced noise and vibration.

China wholesaler Ball Mill Casting Rotary Helical Big Girth Gear Custom Rotary Dryer CZPT High Quality Large Ring Gear gear cycleChina wholesaler Ball Mill Casting Rotary Helical Big Girth Gear Custom Rotary Dryer CZPT High Quality Large Ring Gear gear cycle
editor by CX 2024-01-10

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Double Helical Gear

As one of the leading double helical gear manufacturers, suppliers, and exporters of mechanical products, We offer double helical gear and many other products.

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