Casting of ring gears and gears and how to repair damaged ring gears?

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Casting of ring gears and gears and how to repair damaged ring gears?
Large ring gears are important and indispensable parts of equipment, just like gears. Although the two are similar, their main function is to transmit and change the direction of force. However, in addition to this, the protection of the main body of the machine system by the driving of the ring gear cannot be ignored.
The outer teeth of the large ring gear are divided into two types of tooth shapes: drum teeth and straight teeth. It can change the contact conditions of the teeth and improve the ability to transmit torque, thereby meeting the requirements of cost protection and extending the service life. The large ring gear is a thin-walled ring forging. It is easy to have problems such as uneven wall thickness, folding, and ellipse during the forging process. Therefore, the quality of the casting can be improved by controlling the details of the casting process.
Therefore, it can be said that the large gear ring is a very important component for protecting the service life of the machine. So when the large gear is damaged, how should we repair it?


1. To treat the steel castings, different treatment methods should be used for large gears with different degrees of damage, and the damaged parts of the large gear ring should be treated;
2. Before welding, it should be noted that there should be no impurities such as dirty oil, rust, slag, etc. near the welding part, otherwise it will affect the welding effect;
3. After the welding treatment, there may still be relatively small pores or sand holes on the surface of the steel casting. After removing these defects, the area should be repaired.
4. After the welding treatment, the damaged large gear ring can be used normally again, which not only saves the production cost of the enterprise, but also helps to reduce the loss of resources, which can be said to kill two birds with one stone.

How to extend the service life of rollers

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As a processing and manufacturing tool, rollers are widely used in factories. Their functions cannot be replaced by other roller products. Of course, the quality requirements for rollers are also very high. After the roller is used for a period of time, various wear problems will occur. In serious cases, the roller may not be able to continue working.
The service life of the roller is generally 8 hours. After that, groove wear and crack fatigue will occur. If the grooves caused by wear are deep, steel sticking and jamming will occur. The plasma aluminum guide roller has obvious resistance to abrasive wear and thermal fatigue. After repairing the roller shaft, the effect is obvious. Plasma cladding technology is used to coat the surface of 45 steel with Al2O3-doped Fe-Ni-based high-temperature anti-wear alloy coating, which can improve the anti-wear and anti-cracking performance of the roller. The application of plasma cladding technology on rollers reduces the labor intensity caused by frequent replacement and reduces the wasted steel rolling work time in disassembly, assembly and transportation of rollers, and can increase the amount of steel rolled, saving a large amount of high-quality steel. At the same time, quality problems caused by roller damage can also be avoided.


From the introduction of the above article, we can know the methods to improve the service life of the rollers, which should be of great help to relevant people. There are many types of rollers on the market. The different materials used to make the rollers will have a great impact on the quality of the rollers and also on the performance of the rollers. For roller manufacturers, roller production needs to be carried out according to formal steps. Improper operation during the production process will greatly affect the quality of the rollers.

What is a herringbone gear and what are the advantages of a herringbone gear?

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Helical gears have a lateral force on the axis. In order to eliminate this force, a gear is made into a helical gear with symmetrical opposite directions to eliminate this force. It looks like a herringbone, which is called a herringbone gear for short. Herringbone gears have the advantages of high overlap, small axial load, high load-bearing capacity, and stable operation. The herringbone gear base is used to transmit the torque of the main motor or motor unit to the roller. Herringbone gears cannot be processed by gear shaping or hobbing.
Herringbone gear advantages:


1. Herringbone gears have a high degree of overlap, with at least 2 teeth meshing at any time.
2. The meshing process between the teeth of herringbone cylindrical gears is a transitional process, and the force on the gear teeth gradually increases from small to large, and then from large to small; herringbone gears have high load-bearing capacity and stable operation.
3. Herringbone tooth theory Because the tooth helix angles are in opposite directions in the symmetry direction, there is no or very small axial force.

What are the possible causes of abnormal vibration of the large ring gear of the rotary kiln?

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1. Rotary kiln kiln body parts wear and overall sinking. The rotary kiln is a large-load continuous operation equipment. After long-term operation, the rolling ring, supporting wheel, backing plate and other parts wear greatly, and the uneven foundation settlement causes the overall kiln body to settle. decreases, causing the tooth tip clearance to become smaller, causing vibration. Sometimes, although the overall kiln line does not drop, the support position close to the large ring gear drops, which also causes the large ring gear to vibrate. This is due to the foundation of the support position sinking or being severely worn, or due to improper kiln adjustment.
2. Caused by wear of connecting parts. The ring gear is connected to the kiln body through a spring plate pin. The ring gear itself is manufactured in sections and is integrated into a whole by using countersunk screws. After the pins, countersunk screws, and these connecting parts are worn, the ring gear components will loosen and the local ring gear will sink, which will also cause the tooth top clearance to become smaller and cause vibration. From a maintenance perspective, the only solution is to replace (or tighten) the corresponding screws. Of course, for countersunk screws, from the perspective of design and manufacturing, it is better to make the ring gear as a whole (or tightly connected) instead of connecting it with countersunk screws, so as to fundamentally eliminate the vibration cause (large tooth factor). The fact that the flaps are made to be turned over is another issue. Practice has proved that the large ring gear has a simple tooth shape and a low rotational speed. It can still operate normally after half of the tooth thickness is worn).


3. The cylinder at or around the ring gear is bent, causing the large ring gear to deflect excessively in the radial direction and cause vibration. This is manifested in the fact that during the meshing operation of the large ring gear and pinion, the top clearance is smaller for half a turn and smaller for half a turn. The vibration is also a periodic half-vibration. Therefore, the real cause of vibration is that the top clearance is too small.
4. Problems with the ring gear itself. The top clearance of the transmission gear is generally 0.2-0.25 times the module. Due to its large outer diameter and radial deflection of the large ring gear of the rotary kiln, the top clearance is 0.28 times the module plus 0.5-1mm. At the same time, it is required that the radial runout and axial deflection of the large ring gear should not be greater than 2mm after installation. Most of the large ring gears are caused by runout or deflection. Since the large ring gear is connected to the kiln body through the spring plate shaft pin, the large ring gear itself is made into two half rings and combined into a whole with countersunk screws.
5. Vibration caused by tooth thickness wear. The vibration caused by this reason appears as continuous and rhythmic vibration, which can be observed through the meshing of the large ring gear and pinion.
6. The pinion gear is not installed in place. In most rotary kilns, the large ring gear and the two pinion gears form an equilateral triangle in the ideal meshing state, but the angle has changed after long-term operation.

Repair, installation and maintenance methods and techniques for large gears

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1. Preparation before maintenance and installation Before repairing and installing the large ring gear, the corresponding tools and equipment should be prepared and their integrity checked. At the same time, understand the working principle and structural characteristics of the ring gear to ensure the smooth progress of the maintenance and installation process.
2. Disassembly and inspection of the ring gear When disassembling the ring gear, the operating procedures should be followed to avoid damaging other components. After disassembly, the ring gear should be comprehensively inspected, including tooth surface wear, cracks, deformation, etc., in order to determine the repair plan.
3. Cleaning and Repair When cleaning the ring gear, appropriate cleaning agents should be used to remove oil stains and impurities. Worn or damaged parts should be repaired, such as welding, grinding, etc.
4. Reinstallation and calibration The repaired ring gear should be reinstalled on the machine and calibrated to ensure that the matching clearance and position of the ring gear and other components are correct.


5. Maintenance methods and cycles Routine maintenance of the ring gear includes lubrication, tightening, etc. Appropriate maintenance cycles and methods should be formulated based on the working conditions of the machine and the material of the ring gear to ensure the normal operation of the ring gear.
6. Regular inspection and records The ring gear should be inspected regularly and the inspection results should be recorded. If any abnormality is discovered, it should be handled and recorded in time.
7. Abnormal situation handling: When an abnormal situation is found in the ring gear, the machine should be stopped immediately for inspection, the cause should be found out and corresponding measures should be taken. If you need to replace the ring gear, you should choose a new ring gear with the same specifications and material as the original ring gear.
8. Maintenance safety precautions During the repair, installation and maintenance of the ring gear, safe operating procedures should be followed to ensure the safety of personnel and equipment. At the same time, qualified parts and lubrication should be used
oil, avoid using inferior products or substitutes.
To sum up, for the repair, installation and maintenance of large ring gears of industrial machinery, we should make full preparations, follow operating procedures, conduct regular inspections and maintenance, and when abnormal conditions are discovered
Deal with it promptly. Only in this way can the normal operation of the ring gear be ensured and the service life and working efficiency of the machine be improved.

The Processing Technology and Application Fields of Shafts

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Roller shafts, gear shafts and large machinery non-standard parts are indispensable key components in modern industry. They play a vital role in their respective fields of application, ensuring product quality and performance through precise machining processes.

Rollers are widely used in steel, petroleum, chemical industry, machinery manufacturing and other industries, and withstand the test of heavy load and high-speed operation. Its processing technology involves steps such as material selection, heat treatment, cutting and surface treatment to ensure that the roller has sufficient strength and wear resistance.
As an important component in the mechanical transmission system, the gear shaft is responsible for transmitting power and torque. The processing process includes forging, heat treatment, finishing and gear grinding to achieve high-precision gear shape and Surface Quality. The addition of gear shafts requires strict compliance with technical specifications and standards to ensure transmission efficiency and stability.


Non-standard parts of large machinery are customized according to the special needs of customers and have unique structures and sizes. The processing technology is flexible and diverse, and may involve CNC machining, laser cutting, stamping and other technologies. The processing of non-standard parts requires full consideration of material, process and performance requirements to meet the specific needs of customers. These products play an irreplaceable role in their respective fields. Whether it is the load-bearing and transmission functions of rollers, the transmission function of gear shafts, and customized solutions for non-standard parts of large machinery, they all provide for the development of modern industry. strong support.

Casting process for large ring gear

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The casting process of large gears from professional manufacturers is a delicate and complex project. Starting from the drawings provided by the customer, the technical team will conduct detailed analysis and simulation to ensure the feasibility of the casting process.

Mold making is the first step in casting. According to the design drawings, the mold is carefully prepared using wood molds, sand molds, etc. During the melting and casting process, technicians strictly control the chemical composition and addition of various elements to meet the performance requirements of the gears. During the pouring process, temperature, speed and time are precisely controlled. Make sure there are no bubbles, no inclusions inside the casting, and uniform density. Large-scale casting processing manufacturers will demould the large gear after cooling, and then perform cleaning work such as grinding and sand cleaning to remove surface debris and burrs. Gears also need to undergo heat treatment, such as normalizing, annealing, quenching, tempering, etc., to improve the material structure and improve mechanical properties.

In the finishing stage, the gears undergo turning, milling, grinding and other processes to achieve the required dimensional tolerance and surface roughness requirements. Every step of production is accompanied by strict quality inspection, including
Dimensional inspection, appearance inspection, chemical composition analysis, mechanical property testing, etc. ensure that the final product meets quality standards. Professional manufacturers produce high-quality large gears through advanced casting techniques and strict quality control, providing reliable transmission components for mechanical equipment, automobiles, aerospace and other fields.