100 TPD Cooler Girth Gear in Sponge Iron Plant

The 100 TPD Cooler girth gear is an important component in the rotary cooler system of a sponge iron plant. In the product specification, the module is a millimeter-based measurement of the size of the gear teeth. The Rotary Cooler Dryers’ capacity is the quantity of material it can handle in a single day.The diameter is a key factor that affects the size and power of the entire structure.

TECHNICAL SPECIFICATIONS FOR 100 TPD Cooler GIRTH GEAR

• MODULES – 25 Module
• CAPACITY – 100 TPD Rotary Cooler for Sponge Iron Steel Plant
• CERTIFICATION – ISO9001
• No of Teeth – 132 Nos.
• DIAMETER – 3350 MM
• MATERIAL GRADE – CAST STEEL IS 2708 Grade 2/3, IS 2644 Grade CS 700, GS34CrMo4
• DESIGN – AS PER CUSTOMER PROVIDED (POPURI / IPS / ITC / MEC / LURGI etc.)
• Applications – DRI SPONGE IRON STEEL PLANT FOR ROTARY COOLER DRYER

WHY CHOOSE PIYALI?

• PIYALI GROUP is a manufacturer, supplier, and exporter of high-quality cooler girth gears.
• PIYALI GROUP offers excellent supply and export services that are beneficial to companies looking to supply girth gears from a reputable supplier.
• To produce high-quality girth gears with a high accuracy and precision, PIYALI GROUP employs more experienced workers and engineers.
• PIYALI GROUP conducts quality control procedures to ensure that its products meet or achieve industry standards.

Piyali Group has a team of experienced engineers and technicians to meet the specific needs of their customers. We, Piyali Engineering Corporation, manufacture and export products to the various states of India including Maharashtra, Karnataka, Andhra Pradesh, West Bengal, Odisha, Bihar, Jharkhand, Chhattisgarh, Gujrat, Tamil Nadu, Meghalaya, Tripura, Himachal Pradesh, Haryana, Telangana and others. The company has a modern manufacturing facility in Ghaziabad, Uttar Pradesh, India. The company has a global presence and exports its products to other countries. Some international customers are located in Egypt, Sweden, Jordan, Srilnaka, Canada and the United States.

GEAR MANUFACTURING PROCESS:

With 30 years of experience, PIYALI GROUP is an expert in the manufacturing and processing of rotary Cooler parts. The production of 100 TDP Cooler girth gear involves a number of steps from the raw material’s transformation to the finished product. The basic steps in processing 100 TDP Cooler girth gears are as follows:

STEP 1: Casting simulation 

Piyali Group is a leading manufacturer of industrial equipment and machinery in India, which include girth gears, rotary cooler shells, sugar mill gears, and others.

The casting simulation process used by Piyali Group includes the following steps:

• CAD model design: The first step is to create a 3D CAD model of the component. For designing the model, we use special software which includes essential features such as sprue channels, feeders and gating systems.
• Meshing: Meshing is the process to divide the CAD model into small finite elements using specialized software to analyze individually.
• Material properties: Material properties such as thermal conductivity, specific heat, and viscosity assigns to each element for further processing.
• Boundary conditions: Boundary conditions such as temperature and velocity are specified for each element. This allows engineers to simulate the behavior of molten metal as it flows through the gating system and into the mold.
• Simulation: The simulation uses the special software, which solves the mathematical equations that govern the behavior of the molten metal. The software predicts various parameters such as temperature distribution, flow velocity, and solidification time.
• Analysis: Analysis includes simulation’s outcome to identify potential defects such as shrinkage, porosity, and hot spots. This allows engineers to make changes to the gating system or modify the mold design to eliminate or minimize these defects.
• Optimization: Based on the analysis, engineers can optimize the casting process by adjusting the gating system, mold design, and material properties. This helps to ensure that the casting process produces high-quality components that meet the required specifications.

Piyali Group uses casting simulation to ensure that its cast components meet the highest quality standards and to minimize defects and costs associated with the casting process. Piyali Group is a leading manufacturer of industrial equipment and machinery with experienced and trained staff to deliver high-quality components to its customers.

STEP 2: Casting

Casting is one of the manufacturing methods used for producing gears. It entails pouring molten metal into a mold in order to produce the desired shape and size of the gear. Sand casting is a preferred manufacturing process for girth gears. The procedure includes the use of a sand mold to shape the molten metal into the desired form. The sand mold is packing sand around a pattern that represents the finished gear shape.

CASTING PROCESS:

In the casting manufacturing process, a liquid material is typically pour into a mold, which contains an internal cavity of the desire shape, and allow it to cool down.

• The casting process begins with the creation of a pattern for a mold. In order to make a mold, place a design in the sand.
• Pattern uses the wood, plastic, or metal material to form the same form and size as the gear’s design.
• Pour molten metal into the mold cavity.

The stages in the sand casting process for manufacturing gear are as follows:

WOODEN PATTERN

The first step in the procedure is to create a wooden pattern that is an exact copy of the gear for the casting process.

The steps involved in wooden pattern inspection are as follows:

• Dimensional Inspection: Dimensional inspection allows to check the pattern to ensure that it is of the correct size and shape for the casting. Dimensional inspection uses various precision instruments such as calipers, micrometers, and gauges for measurements.
• Material Inspection: The material inspection is necessary to ensure that it is of high quality and complies with the casting process’s requirements.
• Surface quality: The pattern’s surface must be flawless and free of flaws like knots, fissures, or rough patches.
• Alignment: To ensure that the pattern does not shift during the casting process, proper alignment is necessary.
• Inspection of the pattern assembly: In this type of inspection, the pieces fit together correctly to make sure that there are no flaws in the joints or connections.

PATTERNMAKING

Patternmaking is the process to create a wooden pattern. The first stage is to design the gear. Then create a sketch of the gear with the help of CAD software. Select a suitable wood for the pattern. Cut the wood to the size and shape needed for the pattern. Use a saw, chisel, and other tools as needed to shape the wood. Cut the gear teeth using a gear tooth cutter or another instrument. Sand the design to remove any burrs or rough edges.

MOLDING

Sand mould helps to create design or patterns. Molding is the procedure of pouring liquid into a specific mold to ensure it solidifies in a modified form. Sand and a binding substance packs around the pattern to make a mold. To form the shape of the finished product, the molten or liquid material pours into a mold cavity or hole.

MELTING AND POURING:

MELTING: The foundries typically use the melting and pouring process to cast metal parts such as gears. The melting and pouring process is essential in gear production because it enables the creation of parts with complicated shapes and fine details. It also allows for the use of a wide variety of materials, such as iron, steel, and various alloys, to create gears with varying strengths and properties.

POURING: Pouring is the procedure of pouring molten metal into a mold to form a blank for a gear in the gear manufacturing industry. For making the gear, the molten metal transfers from the ladle into the mould. The pouring process requires proper monitoring in order to ensure that the molten metal flows into the mould and completely fills it.

The pouring process for gear manufacturing as follows:

The first step in the pouring procedure is designing the mould. The exact dimensions and shape of the manufacturing equipment are taken into consideration when making the mould. Once the final mould form is selected, the mould gets ready for pouring. This entails cleaning the mould to remove any grime or debris that is likely to lower the quality of the finished product. The gear blank’s metal goes through a heating process in a furnace or kiln before its manufacture. After melting, the metal is put into the mould. Making sure that the metal pours evenly and that the final product is high-quality is crucial.

Steel Making & Ladle Analysis:

Steel making is a process to create the steel used in gears. In this process, carbon, manganese, silicon, and iron ore are melted together in a kiln to produce molten metal. When the molten metal is prepared, it is poured into a ladle, which is a large container. The metal in the ladle is then examined to ensure that it fits the specifications for use in gear manufacturing. Ladle analysis usually involves measuring the steel’s composition, including the amounts of carbon, manganese, silicon, and other elements.

In the process of making gears, the following steps take place for ladle analysis:

1. Inspection: The first step is to physically check the ladle for any physical flaws, such as cracks or defects. For this, non-destructive testing techniques such as dye penetrant testing or vision inspection are often utilize.
2. Material identification: Understanding the ladle’s material composition  is crucial. The composition of the ladle is capable of having an effect on both the quality of the molten metal and, afterwards, the quality of the gear generates.
3. Sampling: To perform a chemical analysis on the molten metal, it is essential to take out an accurate sample from the ladle. Using this information, it will be possible to determine whether the molten metal’s chemical composition is within the intended range.
4. Chemical analysis identifies the chemical composition of the sample that it takes from the ladle. Various techniques such as spectroscopic techniques use for research purposes.
5. Measurement of temperature: It’s essential to know how hot the liquid metal inside the ladle is. The movement and characteristics of the molten metal can change depending on the temperature, which can have an effect on how well the gear is produced.
6. Degassing is a process used to release any confined gases from the ladle of molten metal.

STEP 3: Blanking

Blanking process in which a flat piece of metal is first cut into the rough form of a gear using a cutting tool, usually a die or punch. In the process of making gears, the blanking process is important as it sets the groundwork for the succeeding processes, including heat treating, finishing, and shaping. There are various techniques to complete the blanking process, including hobbing, broaching, shaping, and milling.  These are:

• HOBBING:  The gear teeth cut into the blank during hobbing using a specialty cutting tool called a hob.
• BROACHING:  To make the gear teeth, broaching is the process of forcing an instrument with numerous teeth through the blank.
• SHAPING: Shape the gear tooth by using a cutting instrument that moves in a circular motion.
• MILLING: By rotating a cutting instrument against the blank, milling removes material and shapes the blank into a gear.

HARD PUNCHING: Using a high-force punching tool, holes or marks appear in the gear teeth or other gear-related components during the hard punching procedure.

STEP 4: Heat treatment

Both heat treatment and grinding, which are two different manufacturing processes, are frequently done in that sequence to give a workpiece the desired properties and measurements.

Heat treatment enhances the hardness, strength, and durability of girth gear, as well as its resistance. Heat treatment is a process that involves subjecting a girth gear to high temperatures which results in a structural change in the material and then cooling it down in a controlled way to improve its mechanical properties. Girth gears undergo a number of thermal treatments, such as annealing, normalizing, quenching and tempering, and carburizing. The type of heat treatment used depends on the material composition of the edge and the desired mechanical properties.]

HEAT TREATMENT PROCESS FOR Cooler GIRTH GEAR AS FOLLOWINGS :

• Annealing: Annealing is a heat treatment process that can enhance the mechanical properties and performance of a material.The purpose of annealing is to reduce the hardness of the material while increasing its flexibility.

• Normalizing: Normalizing is a heat treatment process used on carbon and low-alloy steels. It can enhance the strength, durability, and machinability of the material, making it simpler to work with and less prone to cracks or other types of failure. By normalizing the material, any internal stresses that may have been introduced during earlier production procedures like casting or forging are removed.
• Quenching: An essential step in the heat treament process for girth gears is quenching. It involves quickly cooling the gear to the desired mechanical and microstructure properties after heating it to a specific temperature. The heated girth gear is quickly cooled to below its critical temperature during the quenching process, which results in the formation of a hardened microstructure.
• Tempering: As a crucial step in the heat-treating process for girth gears is tempering that involves reheating the hardened gear to a specific temperature below the austenitizing temperature while maintaining it there for a specified period of time.
• Carburizing: A typical heat treatment process called carburizing is used to increase the surface hardness of metal parts, including girth gears. During the carburizing process, the gear’s surface is exposed to a to carbon-rich atmosphere for a significant period of time. As a result, diffusion of carbon into the metal’s surface layer forms a harder, wear-resistant layer.
• Grinding: Grinding is a machining process that uses abrasive particles to remove a small amount of substance from the surface of the workpiece. Grinding is frequently used to improve the surface finish and dimensional precision of workpieces, as well as to remove surface imperfections that may have appeared during previous manufacturing processes.

STEP 5: Gear Machining

Rough machining is the initial step of girth gear machining. In order to prepare the gear blank for finishing, remove extra material during the roughing process. The final stage of gear production is gear finishing. The optimal procedure for the gear material, black production process, and machining process must be chosen.  Gears must be correct in dimensions and forms to have a high surface finish and be hard and wear resistant for smooth running, good performance, and a long service life.

Finished Machining Process:

• Gear hobbing: The final step in the machining process helps create the girth gear’s teeth. To accomplish this, the gear blank is rotated as a cutting tool is inserted into the gear at an exact angle and depth.
• Gear Grinding: The girth gear is ground after the teeth have been hobbed to make sure the teeth are the right size and form. The surface finish of the gear blades is also improved by grinding, which reduces corrosion and increases effectiveness.
• Final inspection: Several techniques, including eye inspection, ultrasonic testing, and magnetic particle inspection, are used to check the finished girth gear. This guarantees that the gear is free from defects and fulfills the requirements for the application.
• Surface Treatment: To increase the girth gear’s wear resistance and longevity, a surface treatment like nitriding or carburizing is used.

STEP 6: GEAR TESTING

Any defect in the girth gear can seriously harm the machinery and even force the manufacturing process to stop. Large rotating machinery like rotary kilns, ball mills, and cement mills require regular maintenance and care. Girth gear testing is an essential process used in the maintenance and care of these equipments. Regular testing and inspection are necessary to guarantee the girth gear’s reliability and secure operation. There are various techniques used when testing girth gears.

The various gear testing techniques are as follows:

• Ultrasonic testing: This non-destructive testing technique scans the girth gear with high-frequency sound waves to look for interior flaws. Using this technique, sound waves are sent into the girth gear, and the echoes that bounce back are then measured.
• MPI Testing:
• Gear mechanical testing: This testing assess the mechanical qualities of gears is gear mechanical testing. These tests are essential for ensuring that gears operate correctly and securely in the specific applications.
  • Hardness testing: Hardness testing determine the gear material’s hardness, which is a sign of its strength and durability. Brinell, Rockwell, as well as Vickers testing are common hardness testing techniques.
  • Tensile testing: Tensile testing involves applying tension pressures to gear materials until they break in order to determine their strength and ductility.

• Dimension test: The dimension test is one of the critical measurements which includes checking various critical dimensions of the gear, such as tooth size, tooth profile, gear diameter, tooth thickness, and concentricity.
• Chemical test: Gear testing can use chemical analysis to figure out the properties and composition of the gear material. A spectroscope is a tool that identifies the elements that compose the gear material. This test helps assess the material’s cleanliness and find any impurities or pollutants.

TEETH CUTTING PROCESS:

Teeth cutting is an essential process in gear production. It entails removing material from a gear blank in order to make the teeth on the gear. The process typically includes using a cutting tool to remove material from the gear blank in a particular pattern defined by the desired tooth shape.

TEETH CUTTING PROCESS:

1. Hobbing: Gear hobbing is a machining process that uses a hob to cut teeth into a blank, resulting in the desired tool. The cutter and gear blank rotate at the same time to transfer the profile of the hob onto the gear blank. Gear hobbing includes master hob or index hob techniques on CNC gear hobbing machines that cut wheels, gears, pinions, worms, and shafts. 
2. Shaping: The common method of gear shaping involves the process to mount a gear blank in a shaper and using a tool that shapes it like the tooth that needs to be cut.
3. Broaching: The process of “broaching” removes material from the gear blank until the desired tooth profile is obtained.
4. Milling: In the milling process, the cutter moves axially along the length of the gear tooth at the appropriate depth to form the gear tooth.

DRILLING:

Drilling is a machining process used in gear manufacturing to make holes in gears or gear parts. Once the gear blank cut into the required dimensions, then drilling process make holes for the features such as keyholes, bolt holes or oil channels. A variety of tools such as drilling, including twist drills, step drills, and pistol drills. Drilling is an important process in the manufacturing of a gearbox, which helps to ensure the exact dimensions and functions necessary for the correct operation of the gearbox.

STEP 7: FINAL INSPECTION

Final inspection in gear manufacturing is a critical procedure to guarantee that manufactured gears meet the required specifications as well as quality.

DIMENSIONAL TEST:

Final machining dimensional testing is a quality assurance process used to make sure the finished item or component complies with the requirements for its intended use. The method of measuring the accuracy of the finished gear after it has been machined to its final dimension is known as dimensional testing. In the dimensional test, the diameter, the tooth profile and the tooth thickness are measured. These measurements are compared to the design specifications to identify if the gear meets the required specifications.

DP TEST:

A non-destructive testing (NDT) called dye penetrant inspection (DPI) helps to find surface-breaking defects in both metallic and non-metallic materials. Penetrant testing is cost-effective technique for detecting surface flaws in machined parts. It is a common technique for girth gear inspection.

• Cleaning: Clean the surface of the girth gear with degreaser to remove dirt, oil and other impurities.

• Application of penetrant: To penetrate any flaws or cracks, the penetrant is applied on to the gear’s surface.

• Dwell time: The dye remains on the surface for a certain period of time after penetrating any surface flaws or cracks. This dwell period enables the penetrant to completely penetrate any surface flaws and gives the surface time to drain off or remove any excess penetrant.
• Removing excess penetrant: Remove excess penetrant by wiping it off the surface of the girth gear.
• Inspection: Finally, Inspect the girth gear’s surface for any apparent defects.

DP is a useful testing tool for detecting surface defects in girth gears and other components, and can help prevent failures and downtime in industrial applications. Visual inspection takes place with a variety of techniques, including dye penetrant inspection (DPI), visual examination with a magnifying lens, and fluorescent inspection.

STEP 8: PACKAGING AND DELIVERY

Dispatch is the process of making sure the right materials are available at the appropriate time and in the proper quantity to satisfy the production needs of the gear manufacturing. This involves identifying the materials necessary for each production phase, choosing the materials from the stock, and delivering them to the production unit.

Water proof packing:

In order to prevent water or other liquids from entering inside the gear mechanism and causing harm or corrosion, waterproof packing is essential.

• Start by constructing a solid wooden box that is sufficiently big to hold the girth gear and have space for packaging materials.
• In order to protect the girth gear from moisture during transportation, use waterproof material such as plastic sheet or cover.
• Seal the container with a waterproof tape or adhesive to prevent water from entering the container.
• To further guard against moisture, consider including a desiccant packet or moisture-absorbing substance, like silica gel.
• Label the container clearly and concisely, including the recipient’s address, contact information and recipient’s name.

Wooden Box Packing:

A wooden box can be a good choice for packing heavy equipment for storage or transportation. To determine the proper size of the required wooden box, measure the girth gear first. Then choose a large, solid wooden box that can hold the equipment and leave the enough space for protection and security. The box needs to be strong enough to support the weight and pressure of the equipment. To prevent scratches and damage to the equipment during transportation, line the package with a layer of padding material like foam or bubble wrap.

Use strong packaging tape or metal strapping to tightly seal the box so that the items inside cannot shift or move.

DELIVERY:

After completing the whole gear manufacturing process, the product is finally delivers to the customer.

KEY FEATURES:

• A 100 TPD Cooler girth gear is typically large in size, and it must be capable of handling heavy loads and high temperatures.
• H igh-quality cast steel 100 TPD Cooler girth gears ensure its durability and strength.
• The design of the tooth shape of the 100 TPD girth gear ensures smooth and effective power transmission between the driving and driven components.
• Proper lubrication is necessary for Cooler girth gear to ensure that it functions smoothly.
• Regular maintenance is necessary to detect wear or damage and prevent serious problems if they occur.

APPLICATIONS USED:

• Sponge Iron Plant
• Cement Plant
• Chemical Plant
• Carbon Plant
• Sugar and Paper Mills
• Fertilizer Plant