Large steel foundries recommend that you replace the ball mill gear ring in this way

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The gear ring is a component required in many mechanical equipment. It will directly drive the entire equipment to operate. During operation, sometimes a new ball mill gear ring needs to be replaced due to other conditions, which is prone to tolerance jump. So, what are the steps for replacing the gear ring and the reasons for the jump tolerance?

1. Steps for replacing the ball mill gear ring:

(1) The old gear ring will be knocked out of the flywheel body at multiple points with a brass rod in a cold state and removed. Before assembling the new gear ring, try to chamfer the teeth one by one with a file to facilitate meshing and reduce damage.

(2) The gear ring and the flywheel are hot-pressed, with an interference fit of 0.25-0.64mm. During assembly, the gear ring is heated with a blowtorch or welding gun, generally at 300-400°C, and is heat-fitted on the edge of the processed flywheel. Then hammer it in with a hammer or press it down with a hydraulic press. In order to prevent the large gear ring from loosening, the large steel foundry drilled holes every 1200 places and inserted steel pins to fix it.
(3) After the large gear ring is firmly assembled, the chamfer of the wheel teeth needs to be polished. Pay attention to improving the assembly so that the chamfered surface of the ball mill large gear ring faces the crankshaft mounting surface. Drilled 200 holes and fixed with steel nails.

2. Summary of the reasons for the tolerance runout of the large gear ring in the large steel foundry:
(1) The quality of the raw materials used in making the gear ring is very poor.
(2) When the gear ring is used as the workpiece spindle on the machine tool, its rotation accuracy is very low.
(3) When the gear ring is used, the gear ring installed on the tool holder is not positioned well.

If you have a large gear ring processing demand, you can consult us at any time. The large steel foundry will tailor the large gear ring for you according to the drawing!

Precautions and tips for installing the new environmentally friendly rotary kiln large gear ring

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Among all the parts of the rotary kiln, the large gear ring is one of the main parts of the rotary kiln equipment. Since the large gear ring is mounted on the rotary kiln cylinder and drives the operation of the entire cylinder during operation, the installation method is directly related to the use effect and production efficiency of the equipment. So what problems should be paid attention to when installing the large gear ring?
Due to the needs of manufacturing capacity, transportation and installation, the large gear ring is composed of two half gears, connected together with matching screws, and fixed tangentially on the kiln body through a spring plate. Therefore, in order to complete the installation and alignment of the large gear ring with high quality, a scientific and feasible construction plan must be formulated whether it is a new installation or a reset installation after overhaul. The correct installation process is not only responsible for your own safety, but also effectively extends the service life of the rotary kiln.

Installation precautions

1. Before installing and aligning the large gear ring, the center line of the cylinder at the riveted spring plate must be adjusted to the correct position.

2. During the installation and alignment of the large gear ring, the pre-installation of the gear ring is a very critical link. The pre-installation must be of high quality, high standards and strict requirements. The alignment of the gear ring and the cylinder during installation is only “centering” and cannot correct the gear ring.

3. The pre-installed large gear ring must be hoisted as a whole, otherwise the pins and bolts at the gear ring are difficult to install and tighten, and the pitch error at the interface and the roundness tolerance of the gear ring cannot be guaranteed.

4. The spring plate and the cylinder must fit tightly in a free state. The spring plate and the cylinder must not be fixed or riveted forcibly. Otherwise, after loosening the spiral top and drawing the wire, the radial and end face runout of the gear ring will increase or the error will exceed the standard under the action of the spring plate.

5. The radial and end face runout values ​​during fine alignment must be less than the standard values. After removing the spiral top and drawing, the radial and end face runout of the gear ring may increase, but the difference will not exceed the standard.6. When drilling the spring plate and the cylinder, proceed in sequence, and tighten a positioning bolt for each hole drilled.

7. After the rotary kiln is delivered for overhaul and put into production for 12h to 24h, the kiln should be stopped to check the rivets of the spring plate and tighten the screws of the large gear ring for a second time.

Understand the processing technology of gear parts in one article

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Gears, as the basic and key components in the mechanical field, play a vital role in various mechanical equipment with their unique structure and function. This article will discuss the processing technology of gears in depth, in order to provide reference for professionals in related fields.

Basic structure and function of gears
Gears are mechanical parts with toothed shapes, which transmit power and motion by meshing with each other. Gears are composed of two major parts: the ring gear and the wheel body. Gears with different functions will be different in design, but the basic structure remains the same. Common types of cylindrical gears include disc gears, sleeve gears, internal gears, shaft gears, fan gears and racks, among which disc gears are the most common due to their wide application.

Precision requirements for gears
The manufacturing accuracy of gears directly affects the working performance, load-bearing capacity and service life of mechanical equipment. According to the conditions of use, gear transmission needs to meet the following accuracy requirements:
1. Motion accuracy: ensure that the gears can accurately transmit motion, maintain a constant transmission ratio, and limit the angular error within a certain range.
2. Working stability: The gears are required to be stable during movement, reduce impact, vibration and noise, and limit the change of angular error in a short period.
3. Contact accuracy: Ensure that the gears have uniform contact on the tooth surface when transmitting power to avoid premature wear caused by uneven load distribution.
4. Tooth side clearance: Leave an appropriate gap between the non-working tooth surfaces to store lubricating oil and compensate for dimensional changes and processing and assembly errors.

Material selection of gears
The material selection of gears has a direct impact on their processing performance and service life. Common gear materials include medium carbon steel, low and medium carbon alloy steel, and for gears with higher requirements, special materials such as nitrided steel may be selected. Non-power transmission gears can also be made of cast iron, cloth-reinforced bakelite or nylon.

Heat treatment process of gears
The heat treatment process in gear processing is mainly divided into two types:
1. Blank heat treatment: Normalizing or tempering treatment is performed before and after the gear blank is processed to eliminate residual stress, improve the machinability of the material, and improve the mechanical properties.
2. Tooth surface heat treatment: After tooth processing, carburizing quenching, high-frequency induction heating quenching and other processes are often used to improve the hardness and wear resistance of the tooth surface.

Gear tooth processing method
Gear tooth processing is the core link of gear processing, including forming method and development method. The forming method uses forming tools that match the tooth shape, such as milling, pulling and forming grinding. The development method is that the gear tool and the workpiece perform development movements according to the meshing relationship, such as hobbing, gear shaping, shaving, grinding and honing.

Tooth end processing
Tooth end processing includes rounding, chamfering, chamfering and deburring. These processes can reduce collision, remove sharp edges and burrs, and improve the meshing performance of gears.

Gear precision requirements
The manufacturing accuracy of gears directly affects the working performance, load-bearing capacity and service life of mechanical equipment. According to the conditions of use, gear transmission needs to meet the following precision requirements:
1. Motion accuracy: ensure that the gear can accurately transmit motion, maintain a constant transmission ratio, and limit the angular error within a certain range.
2. Working stability: require the gear to be stable during movement, reduce impact, vibration and noise, and limit the change of angular error in a short period.
3. Contact accuracy: ensure that the gear tooth surface contacts evenly when transmitting power to avoid premature wear caused by uneven load distribution.
4. Tooth side clearance: leave an appropriate gap between non-working tooth surfaces to store lubricating oil and compensate for dimensional changes and processing and assembly errors.

Material selection of gears
The material selection of gears has a direct impact on their processing performance and service life. Common gear materials include medium carbon steel, low and medium carbon alloy steel, and for gears with higher requirements, special materials such as nitrided steel may be selected. Non-power transmission gears can also be made of cast iron, cloth-reinforced bakelite or nylon.

There are two main types of heat treatment processes in gear processing:
1. Heat treatment of blank: Normalizing or tempering treatment is performed before and after gear blank processing to eliminate residual stress, improve material machinability, and improve mechanical properties.
2. Tooth surface heat treatment: After tooth shape processing, carburizing quenching, high-frequency induction heating quenching and other processes are often used to improve the hardness and wear resistance of the tooth surface.

Processing process of spur gears

The processing process of high-precision gears includes blank forging, heat treatment, profile processing, tooth surface processing, chamfering, deburring, high-frequency quenching, key slot insertion, grinding and other steps, each of which has an important impact on the performance of the final gear.

Gear processing process analysis

In the process of gear processing, the selection of positioning reference, processing of gear blanks, and processing of tooth ends are all key links. Correct positioning reference can improve production efficiency and processing quality, and the processing of gear blanks provides the necessary reference for subsequent tooth surface processing and testing.

Through a comprehensive analysis of the gear processing technology, we can better understand the complexity and sophistication of gear manufacturing, and how to ensure the performance and quality of gears through precise process control. In actual production, every detail cannot be ignored, only in this way can high-quality gears that meet the requirements be manufactured.

A comprehensive analysis of gear shaft design and its processing technology

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As the core component in the mechanical transmission system, the gear shaft plays an important role in transmitting motion, torque or bending moment. They are usually metal round rods with different diameter segments to adapt to different mechanical needs and operating conditions. This article will explore the application, design points and processing process of gear shafts in depth.

1. Application of gear shafts
The use of gear shafts usually follows the following situations:
（1）Suitable for small gears, that is, gears with fewer teeth.
（2） Common in high-speed, that is, low-torque application scenarios.
（3）Rarely used as a sliding gear for speed change, in most cases it is a fixed running gear.
（4）The shaft and gear are usually combined into a whole. When designing, the length of the shaft should be shortened as much as possible to reduce the difficulty of processing and improve the mechanical strength.

2. Key points of gear shaft design
When designing a gear shaft, the following points need to be considered:
（1）-The length of the shaft should be as short as possible to facilitate processing and support.
（2）-The mechanical strength of the shaft, such as rigidity, deflection and bending resistance, should be guaranteed.
（3）-The machining accuracy requirements of the gear shaft are usually low, and high-precision machine tools are not required.

3. Processing process of gear shaft
The processing process of gear shaft includes the following key steps:
（1）Forging and blanking: Hot die forging is a widely used forging process for gear blanks. Wedge cross rolling technology is also used in shaft processing. It has the characteristics of high precision, small machining allowance and high production efficiency.
（2）Normalizing treatment: The purpose is to adjust the hardness, prepare for subsequent gear cutting, and reduce heat treatment deformation. Isothermal normalizing process is usually used.
（3） Turning: CNC machine tools are used for turning to ensure the verticality of the inner hole and the cross section to meet the positioning requirements of high-precision gear processing.
（4） Hobbing and gear shaping: Ordinary hobbing machines and gear shaping machines are used to process the gear part. Although the production efficiency is relatively low, with the development of coating technology, the service life of the tool has been extended, reducing the number of tool changes and tool grinding time.

4. Precision and efficiency of gear shaft processing
Although the machining accuracy of the main working surface of the gear shaft is high, it can be processed by grinding under conventional production conditions. This processing method not only meets the precision requirements of the gear shaft, but also ensures production efficiency.
The design and processing of gear shafts are key links to ensure the performance of mechanical transmission systems. Through reasonable design and efficient processing technology, gear shafts that meet both precision requirements and good mechanical properties can be produced. With the advancement of manufacturing technology and the application of new materials, the processing technology of gear shafts will continue to be optimized to meet higher efficiency and stricter quality standards.

On the difference between forged gears and cast gears

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With the enhancement of forging technology and the lightweight requirements of automobiles, cast gears have gradually been eliminated by gear companies, and the automotive gear manufacturing industry has begun to apply more forging forming technology. Gear precision forging forming is a high-quality, efficient and low-consumption advanced manufacturing technology. In recent years, it has been widely used in the mass production of automotive toothed parts.

Characteristics of forged gears:

1. The internal structure of forged gears is dense, high strength and long life.

2. Not only is the appearance beautiful, the working hardness is also greatly improved, and it contains very few impurities.

3. The explosion-proof performance is more reliable and higher in level, and can be used in strict working conditions.

Characteristics of castings:

1. The internal structure of castings is worse, the strength is low, and it is easy to have sand holes, shrinkage, and easy to break and deform.

2. It can be used under general working conditions, and the explosion-proof level is lower than that of forging process tools.

3. There are more oxide scales on the surface, and it is difficult to remove them even with oxide scale cleaning machines.

At present, the country advocates green environmental protection, and castings have gradually been listed as obsolete series. Those who have the conditions have changed from casting to forging. Because of market demand, it is normal for everyone to face transformation. The greater the demand, the higher the requirements for the process, so if you want higher precision gears, you can add Litai oxide skin cleaning machine.