Failure Analysis Of The Girth Gear Of An Industrial Ball Mill

Gear cutting of a split girth gear for a cement mill having an input power of 2200 hp 5 separate mill a damage to mill cylinder neck or stub endanger girth gear and pinion repairs entail extra work for girth gear dismantling b damage to mill cylinder cannot endanger gear teeth mill repairs do not entail gear dismantling kaanu fac tu re 6

We can clean a girth gear set in under 1 hour and inspect the same in under 9 hours saving valuable downtime and increasing production revenue we provide an onsite failure analysis as per agma 1010f14 of the failure modes present if any their severity and how these might impact the operational function of the mill

The 103degree c temperature difference across the mill drive pinion gear was also considered excessive and indicative of severe pinion to girth gear misalignment the misalignment conditions gear loading and bearing distress were all confirmed using vibration analysis subsequent overhaul and realignment of the drive train reduced the

Girth gear of ball mill the girth gear is the major component used in rotary kiln and ball grinding mill which is required to be operated in a long time so the quality requirements during the actual production for the big gear

Being a ball mill maintenance services company part of our role is to inspect the gears pinion and girth gears may appear to be robust pieces of the machine however without careful monitoring of mesh alignment and lubrication systems these expensive items quickly degrade and can ultimately fail in spectacular fashion

At work in virtually every industrial process available in every possible shape and size gear units and drivelines face an extremely wide range of operating requirements and conditions regardless of industry or application all industrial transmissions share a common set of challenges they must perform as reliably efficiently and cost

May 01 2014nbsp018332we have gearbox premium make model spl md2760 fitted with girth gear of cement mill and motro kw is 3150 994 rpm girth gear is 2 years old and gearbox is new we are facing vibration in de 7mm and nde of input shaft is 45mms can you tell what may the problem

Ball mill slag mill coal mill raw material mill cement mill rod mill casting parts slag pot cast steel nodes bearing chock for coal mill girth gear moregtgt partsampservice parts technical service surfacing service solutions production line lime production line ggbs production line chaeng won the quotfourstar industrial enterprise of 2019

Jan 01 2013nbsp018332the service life of bearings is expressed either as a period of time or as the total number of rotations before the occurrence of failures in the inner ring outer ring or in rolling element ball or roller because of rolling fatigue due to repeated stress rated life of bearing expressed as the period at which equipment or machine element fails under specified condition of use given by its

The images below are provided to help you make an accurate differential failure analysis a visual inspection of the failed or damaged ring and pinion gears andor bearings will usually indicate the cause of most failures normal ring and pinion wear the tooth surface on the ring and pinion gears is only moderately shiny

Lubricant discolored bluelbrown ball trah and balls are swptoms failure of lubricant failure eiceisive wear i of balls ring and cages will follow resultina in overheatinn and balls wfll also be bluehkk subseqgent catastrophlc failure ball bearings depend on the continuous presenceof a very thinmillionths of an inchfilm of

Aug 18 2015nbsp018332the girth gear of ball mill is the major component used in rotary kiln and ball grinding mill which is required to be operated in a long time so the quality requirements during the actual production for the big gear ring are very high

Rotary kiln kiln tyre girth gear amp pinion for kiln support roller with shaft assembly for kiln horizontal ball mill mill headends trunnion girth gear amp pinion for ball mill and bearings base vertical roller mills foundation frames internals components amp trial assembly

The size of the motor can be determined by the following formula where p inch is the incher driver power hp or kw n oinch is the requested ouput speed of the mill gear in inching mode n omill is the actual output speed of the mill gear in normal running mode p millmotor is the actual power of the main drive motor or 2 x main drive motor

Failure analysis reporting from basic to full reporting including material analysis gear design new and auditing the design for old gears designing and fabrication of gear cases etc to suit existing spare gear sets design and supply of girth gears and pinions girth gear design project engineering and supply of new equipment

14 foundations for industrial machines and earthquake effects exposed to dynamic loads which depends on the speed of the machine and natural frequency of the foundation thus a vibration analysis becomes necessary each and every machine foundation does

The kiln girth gears are available mainly in bipart four parts 8 parts or multi segments as per the requirement and suitability with the application of gear in the field of grinding mill components we supply mill headsfeed inletgrinding rollercement kiln riding ring casting gears shaft block also we supply mill shell of welding

For each failure mode what are the failure effects fmea general fmeca severity and probability assessments these two questions alone guide classical fmea these filtering questions shorten the analysis and conserve manhours treat interfaces at each level of analysis as system elements at the same that level

Gear failure often follows bearing failure gear tooth contact patterns complete this step before disassembling gearbox components for inspection the way in which mating gear teeth contact indicates how well they are aligned figure 1 if practical record tooth contact patterns under either loaded or unloaded conditions

2 gear distress and failure modes distress or failure of gears may be classified into four categories 1 surface fatigue pitting 2 wear 3 plastic flow 4 breakage the appearance of the various distress and failure modes can differ between gears that have through hardened teeth and those that have surface hardened teeth

The burned clinker is then fed into either horizontal or vertical ballroller mill fatigue life prediction analysis was carried out on girth gear girth gearpinion assembly 11 ball

Girth gear for rotary kiln and ball mill manufacturer chaeng the girth gear is the main component of the rotary kiln and the ball mill it needs to drive the entire cylinder to run therefore in actual production the quality requirements of the girth gear are very high

The fatigue in the gears induces the formation of cracks in the root of the gear tooth which propagates with each rotational cycle of the gear and ultimately leads to the failure of the gear tooth pitting this is a major cause of gear failure accounting for nearly 60 of the gear failures pitting is the formation of craters on the gear tooth

May 17 2018nbsp018332failure modes can involve bearing failures or gear failures or both lubrication modern industrial gears use an involute tooth form and tooth engagement which is a combination of rolling and sliding suspected cause of failure maintenance history vibration analysis results and oil sample analysis results once the reducer is in the

Girth gears fall into two basic categories flange mounted and tangential spring mounted flangemounted girth gears the more common of the two are most frequently utilized in cold processing equipment such as sag semi autogenous grinding mills and ball mills for use in the mining and cement industries by current standards girth

Aug 03 2020nbsp01833234 x 20 sag mill nameplate mill power hp 17000 motor power hp max 8985 face width mm 1016 mill speed rpm nominal 103 gear ratio 202 mesh per revolution 20 operating hours at first detection 35345 gear tooth load cycles 43686420 march 2016 detecting cracks with astm e 2905 a complete cleaning and girth

511 the purpose of using an eddy current array for mill girth gear tooth examination is it drastically reduces the examination time covers a large area in one single pass provides realtime cartography of the examined region facilitating data interpretation and improves reliability and probability of detection pod one tooth can be examined in less than 30 seconds

Large girth gears are installed around the cylinder to rotate the horizontal ball mill cylinders a pinion connects these directly to the industrial gear unit seweurodrive does not just provide industrial gear units we provide the complete drive package with specially segmented girth gears

During mill equipment failures such as a broken discharge grate opportunities for improved mill control based on ball mill analysis of the vibrating sensor data from this installation is currently underway and some preliminary findings from this installation are presented adjacent girth gear or on the shell of the mill alternatively

Apr 01 2015nbsp018332in hot rolling mills premature failure of rolls is a major concern as it adversely affects the mill operation as well as production analysis of failed roll materials and actual rolling conditions in service are therefore necessary to understand the roll failure mechanism and thereby improve the wear resistance and extend the service life of rolls