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Casting Steel Large Half Ring Gear for Cement Mill

Material:ZG42CrMo,ZG35CrMo,SCCrM3B,SCMn2A
Application: cement mill,coal mill,sugar mill
Size: OD1200mm to 12000mm
Module:10-50
Weight: 3 to 70 tons
Status:pre-machined or finished machining
Class certificate:ABS,CCS,NK,LR,DNV,RINA,BV,KR
Payment terms:T/T or L/C
Availability:
Quantity:

Material

MaterialCSi
MnPSCrMo
ZG42CrMo0.38-0.43
0.15-0.350.75-1.00≤0.035
≤0.035
0.80-1.100.15-0.25



Material StandardGB, EN, DIN, ASTM, GOST, JIS, ISO
Weight3-70 tons
Heat treatment
Normalizing+tempering+surface hardening


If surface hardening is needed,we can do it by our sub-contrator.

But better not ask for surface hardening.

I only believe our own equipment and everything is under control.

Hardening by sub-contractor can be as smooth as in our own workshop.


ZG42CrMo or ZG35SiMn is common material for gear and kiln tyre.





Prodution process

No.
Equipment Name
Quantity(Set)
1 Transformer substation 1
2 Full set of wooden molding equipment 10
3 Sodium silicate sand mix line 4
4 Alkaline phenol resin sand mix line 2
5 25 tons Electric arc furnace 1
6 50 tons Intermediate frequency furnace 2
7 120 tons Refining furnace 1
8 120 tons VD furnace 2
9 12m*9m*6m Heat treatment furnace 3
10 120 tons Large-scale shot blasting machine 1
11 150 tons Travelling crane 2
12 125 tons Travelling crane 3
13 200 tons Travelling crane 2
14 CNC gantry boring and milling machine 2
15 2.5m-10m Digital vertical lathe 16
16 Boring and milling machine 13
17 Horizontal lathe 3
18 Large dust removal equipment 7

1)The engineer will firstly prepare the technology and do a simulation before pouring.

1642741044(1)


2)We will make a pattern of the half gear based on engineer's technology.

It will cost us around one week.

After that the engineer will check the dimension and make a record.

P11-1

3)Sand molding making will be made by experienced wokrers.

IMG_20180619_091321

4)Pouring and cooling.

There are one 8tons electrical arc furnace;

Two 50 tons medium frequency furnace;

One 120 tons refining furnace and one 120 tons VD furnace;

5)Clean the sand and cut the riser before heat treatment

6)Heat treatment will cost 7days( 4 days normalizing and 3 days tempring).

There are 8 heat treatment furances with max. one is 12m*9m*6m.

热处理炉

7)dimension check and draw a line for machining.

IMG_2136

8)Rough machining

IMG_2714

9)NDT withe qualified inspector

磁粉照

10)Welding repair if needed and tempering for stress relief

11)Final machining and NDT

12)Customers' inspection and packing

15



About Haitai

P5

Haian Haitai Casting Co.,Ltd. is established in 2003. 

We supply large steel castings with low carbon or alloy steel from 3 tons to 150 tons per piece.

With a quick development,now we had supplied steel castings 6,000 tons per month.

There are three workshop for sand mold making,one workshop for machining and one for post procedure.

Our main products are for cement mill(around 30%).

We supply around 400pcs kiln tyres,170 sets of ring gears and 930pcs supporting rollers a year.

We also have rich experience of the castings for shipbuilding with 9 class certificate.


Half gear is our fist product.

We make it a lot in one year.

Kiln tyre,supporting roller and half gear are the castings we make everyday.

We accumlated lots of experience for them and can fix any problem.

For our own technology,we can make it for woking area without any welding.

It is our speical,we get this kind of special by thousands of making.

That is also most of time it is forbidden to go through our sand mold making workshop carefully.

We have our own technology and not open to customers.

We grow up together with our customers.

Our customers will ask for higher technical requirement than before,

we should improve our skills to meet their requirement and challange the market


We supplied small half gear for Bolivia for ball mill.

The hlaf gear can be quicked finished with gear cutting around two and half months.

For bigger ones,we need more time to finish it.

The gear cutting is finished by nearby sub-contactors.


Testing Equipment

No.
Equipment Name Quantity(Set)
1 Sand analysis equipment 1
2 Impact sample low temperature meter 1
3 Direct reading spectrometer(OXFORD) 2
4 ONH analyzer 1
5 ZEISS metallurgical microscope 1
6 Pendulum impact tester 1
7 Microcomputer controlled electro-hydraulic servo universal test machine 5
8 Various hardness tester 4
9 Magnetic defect detector 5
10 Ultrasonic flaw detector(digital) 1
11 CX-52 Total station 1
12 Stylus roughness meter 1


We do the test according to diffrent production step,

such as chemical composition,UT,MT and mechanical property.

In 2021,Haitai inspection and testing center got approval from CNAS.


P6-3

P10-1

P10-3

Delivery

Our company is near to Shanghai port and we can supply different packing according to customers' specification.

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