INTRODUCTION

Girth gears are manufactured from segments. A girth gear is divided into 816 segments, which are joined by bolts. The segment length typically varies between 0.81.6 m. Short segments enable the use of small versatile and accurate machines. Due to this, optimal and precise tooth reliefs can be produced. Casting of short segments is easy, securing high and even material strength properties. Segments are interchangeable, which reduces spare part costs. Short segments also enable easy and cost-efcient transportation.

1 2 3 b da dmax

girth gear pinion segment face width tip diameter max. drum diameter

Picture 1. Terms and denitions of an open gear

A girth gear can be single or double pinion driven. A pinion is manufactured as a single part with an integrated shaft. The pinion can also be separate and mounted on a separate shaft, supported by bearings, or on the output shaft of the main gear unit.

The rotation speed of a drum normally varies between 0.520 rpm corresponding to the peripheral velocity from 0.3 to 10 m/s of the girth gear. The nominal power of a standard Kumera girth gear is up to 8 MW per mesh, i.e., 16 MW when double pinion driven.

GEAR TECHNOLOGY
The manufacturing method of girth gears enables wide possibilities for geometry modications. Typically, the tooth geometry is according to Table 1. Pinion anks are modied by tip, root and end reliefs. The modications compensate the deection of the drive system, thus high contact pressure on the tooth edges can be avoided.

Table 1. Typical geometry of a girth gear

Min. Module Pressure angle, [] Helix angle, [] Number of teeth: Girth gear Pinion Face width, [mm] Reference diameter [mm] Quality Girth Gear Pinion 100 18 100 2000 ISO 810 7 300 30 500 no limitation AGMA 97 10 0 45 20 Max. 40 Standard 27 24 0

The tooth load carrying capacity can be calculated according to the following standards: ANSI/AGMA 6004-F88 Gear Power Rating for Cylindrical Grinding Mills, Kilns, Coolers and Dryers

ISO 6336 Calculation of load capacity of spur and helical gears DIN 3990 Calculation of load capacity of cylindrical gears



GEAR TECHNOLOGY
Table 2. Minimum service factors according to AGMA 6004 (* < 1.5 rpm)
Application Coolers Dryers Kilns Grinding Mills: Ball Autogenous Rod 1.5 1.5 1.5 2.25 2.4 2.5 Durability, CSF 1.00 * 1.00 * 1.00 * Strength, KSF 1.5 * 1.5 * 1.75*

A girth gear can be assembled to a drum with a anged connection or with spring elements.

Picture 2. The FE-method is utilized for deformation and stress calculation of a whole girth gear including the strength calculation of the xing structure

MATERIALS
A common material for girth gears has been spheroidal graphite cast iron EN 1563 GJS 800-2. Nowadays, austempered ductile iron, ADI, EN 1564 GJS1000-5 is more and more used. Its principal attribute is its high strengthto-weight ratio. In the past, pinions were often made from through-hardened steel. At present, the standard material for Kumera pinions is case-hardened 17CrNiMo7-6. Teeth are ground after heat treatment. The pinions have a substantially improved load-carrying capacity, better quality of teeth, and good surface quality of tooth anks, resulting in better operational reliability. Pinions are also less wide with the same nominal output torque, which improves the load distribution across the face width.

Table 3. Material properties

Tensile strength [N/mm2] Allowable contact stress [N/mm2] Allowable bending stress [N/mm2] Youngs modulus [kN/mm2]

Material

Hardness

Girth gear EN 1563 GJS 800-2 EN 1564 GJS 1000-5 (ADI) Pinion EN 10084 17CrNiMo7-6 5862 HRC 1200 1500 500 206 280320 HB 300360 HB 800 1000 700 1200 248 320 185 159



MATERIALS, ADI
The standardization of the ADI material has proceeded in recent years, which facilitates its use. The standards ASTM A897/A897M-06, EN 1564:1997, and ISO 17804:2005 outline the ADI grades varying in mechanical properties. The information sheet AGMA 939-A07 Austempered Ductile Iron for Gears covers the areas of designing, purchasing specifying and verifying the ADI material, in particular for applications in gears and power train components. ADI is produced by heat treating ductile iron, using the austempering process. Austempering is a specialized, isothermal heat treatment. When compared to conventional ductile iron, ADI can have over twice the strength for a given level of ductility. ADI can have a fatigue strength comparable to that of cast and forged steels. ADIs strength can be greatly enhanced by subsequent grinding, llet rolling or shot peening. The ausferrite matrix in ADI undergoes a strain transformation hardening when exposed to a high normal force. This same strain transformation hardening is what gives ADI a better wear resistance than the bulk hardness would indicate. Other attributes of ADI material include good noise dampening, fracture toughness, low temperature properties, and reasonable stiffness. ADI has a 20 % lower Youngs Modulus than steel. In gears, this results in a larger contact area for a given input load. In some cases, this has been shown to reduce contact stress and noise.

Table 4. Properties of different ADI-grades

ADI Herzian resistance Bending resistance Machinability Shot peening Load capacity Moderate Exceeds ductile iron Competes with throughhardening Exceeds throughhardening Competes with nitrided steel 750 Modest Very good Very good Good 900 Moderate Good 1050 Fair Good Good Good High Exceeds ame hardening Very high Competes with case hardening 1200 Good Fair 1400 Good Modest 1600 Very good Poor Poor

LUBRICATION
The most common type of operational lubrication is automatic interval spray lubrication, where the applied lubrication volume is controlled by the spray as well as pause times. If a drum is rotated by a girth gear before the lubrication system is taken into operation, priming lubrication is recommended. A priming lubricant prevents damage during initial operation. The priming lubricant is applied once to all tooth anks by a brush or spatula. Based on experience, it can be stated that a girth gears rolling strength and scufng load capacity are improved by reducing ank roughness and increasing the effective contact ratio. During the running-in period, limited wear is intentionally produced at the tooth anks, which improves the tooth surface roughness and further increases the load contact area. During the running-in, increased lubricant throughput is necessary to ush out the initial metal wear generated through the removal of the surface peaks and high spots during the rst stages of the process. An average runningin time is 300 hours.

Table 5. Lubricant consumption for running-in and operational lubrication

Application Rotary drum drives (coolers) Single pinion kiln drives Single pinion mill or kiln drives Single pinion mill drives and double pinion kiln drives of large dimensions Double pinion mill drives Consumption (g/cm/op. hour.) Running-in 4 5 6 7 8 Operational 1.0 1.5 1.5 2.0 2.0 2.5 2.5 3.0 3.0 3.5



SELECTION
Selection
Determine the minimum diameter of the girth gear (table 9) ddrum < dmax Determine the required girth gear selection torque Tdrum * KA = T2D If the required drum torque is not known, it can be calculated from motor power Tdrum = 9,550 * P1 * / n2 Select ratio, face width, and material in accordance with the equation below T2D < T2* fw* fd

Selection example
Application: Outer diameter of drum: Input power of drum: Rotation speed of drum: Main gear unit: Smallest possible girth gear: Application factor: Drive number factor: Efciency of drive: Drum torque: kNm Selection torque of drum: Select girth gear from table 7: Selected girth gear: Material: Tip diameter of drum, da: Number of teeth of girth gear, z2: Number of teeth of pinion, z1: Girth gear ratio, i: Face width of girth gear, b: Kiln ddrum = 4500 mm P1 = 2 * 200 kW (double pinion) n2 = 1.4 rpm, three-stage ddrum < dmax, dmax = 4600 mm KA = 1.75 fd = 1.95 = 0.96 Tdrum = 9,550 * (2 * 200) * 0.96 / 1.4 = 2619 T2D = 2619 * 1.75 = 4583 kNm T2D < T2* fw* fd, 4583 < 2050 * 1.95 * 1.19 GJS-1000-5 (ADI) 5346 mm 196 18 10.89:1 380 mm

SELECTION
Symbols
ddrum dmax Tdrum KA T2D T2 P1 n2 z1 z2 i fw fd outer diameter of drum, [mm] max. diameter of drum, [mm] drum torque, [kNm] selection factor, (table 6) girth gear selection torque, [kNm] nominal torque of girth gear, [kNm] (table 10) input power of drum drive, [kW] drum speed, [rpm] number of teeth of pinion number of teeth of girth gear open gear ratio face width factor, (table 7) drive number factor, (8) efciency, (table 9)

Table 6. Selection factor, KA

Application Coolers Dryers Kilns Grinding Mills: Ball Autogenous Rod 2.25 2.4 2.5 Selection factor, KA 1.5 1.5 1.75

Table 7. Face width factor, fw

B, [mm] Factor 100 0.38 140 0.52 180 0.65 220 0.78 260 0.89 300 1.00 340 1.10 380 1.19 420 1.27 460 1.34 500 1.40

Table 8. Drive number factor, fd

Single drive Double drive 1 1.95

Table 9. Approximated efciency,

Number of stages including girth gear efciency 1 0.99 2 0.98 3 0.97 4 0.96 5 0.95



SELECTION
Table 10. Selection table for girth gear
Geometrical data GJS-800-2 n2 [rpm] dmax, [mm] 2450 da, [mm] 3078 3456 3834 4212 4590 4968 5346 5724 6102 6480 6939 7344 7749 8127 z2 112 126 140 154 168 182 196 210 224 238 255 270 285 299 z1 18 24 30 18 24 30 18 24 30 18 24 30 18 24 30 18 24 30 18 24 30 18 24 30 18 24 30 18 24 30 18 24 30 18 24 30 18 24 30 18 24 30 i 6.22 4.67 3.73 7.00 5.25 4.20 7.78 5.83 4.67 8.56 6.42 5.13 9.33 7.00 5.60 10.11 7.58 6.07 10.89 8.17 6.53 11.67 8.75 7.00 12.44 9.33 7.47 13.22 9.92 7.93 14.17 10.63 8.50 15.00 11.25 9.00 15.83 11.88 9.50 16.61 12.46 9.97 1 34 47 63 39 54 73 44 62 84 50 66 90 55 73 100 60 81 110 65 89 120 71 96 130 76 100 135 81 105 145 88 115 160 93 125 170 99 130 185 100 140 185 5 180 255 335 205 295 395 235 340 455 260 360 490 290 405 550 315 445 610 345 490 670 370 535 730 400 550 760 425 590 820 460 645 895 490 690 960 520 740 1000 550 745 1000 10 P [kW] 370 535 705 425 625 830 480 720 955 535 765 1000 595 855 1150 650 950 1250 705 1000 1400 765 1100 1500 820 1150 1600 875 1250 1700 945 1350 1850 1000 1450 1950 1050 1550 2050 1100 1550 2050 765 1100 1450 890 1300 1700 1000 1500 1950 1050 1600 2150 1200 1800 2400 1300 1900 2600 1400 2100 2850 1500 2300 3100 1600 2300 3150 1700 2500 3150 1850 2700 3350 1950 2900 3500 2100 3100 3650 2150 3050 3550 20 10 T2[kNm] 355 510 675 405 600 795 460 690 915 510 730 985 565 820 1100 620 905 1200 675 995 1300 730 1050 1450 780 1100 1500 835 1200 1650 900 1300 1750 960 1400 1900 1000 1450 1950 1050 1500 2000 125 130 130 140 145 145 155 160 160 170 175 175 185 190 195 205 205 210 220 220 225 235 235 240 250 255 255 255 260 265 275 280 280 290 295 300 305 310 315 320 325 330 GJS-1000-5 (ADI) n2 [rpm] 1 5 635 645 650 710 720 730 785 800 805 865 875 885 940 950 960 1000 1000 1000 1050 1100 1100 1150 1150 1150 1200 1250 1250 1250 1250 1300 1350 1350 1350 1400 1450 1450 1500 1500 1500 1550 1600 1600 10 P [kW] 1250 1250 1250 1400 1400 1400 1550 1550 1550 1700 1700 1700 1850 1850 1850 2000 2000 2000 2150 2150 2150 2250 2300 2300 2400 2450 2450 2500 2500 2500 2650 2650 2650 2800 2800 2800 2950 2950 2950 3100 3100 3050 2450 2500 2500 2750 2800 2800 3050 3050 3050 3350 3350 3350 3600 3600 3600 3900 3900 3900 4150 4150 4150 4450 4450 4400 4700 4650 4650 4800 4800 4750 5150 5100 5000 5400 5350 5250 5650 5600 5500 5900 5800 5700 20 10 T2[kNm] 1200 1200 1200 1300 1350 1350 1450 1500 1500 1600 1650 1650 1750 1750 1800 1900 1900 1900 2050 2050 2050 2150 2200 2200 2300 2300 2350 2350 2400 2400 2550 2550 2550 2700 2700 2700 2800 2800 2800 2950 2950 2950

2850

3200

3600

3850

4250

4600

5000

5400

5650

6100

6500

6900

7300

10

INSTALLATION, MAINTENANCE
The allowable radial and axial runout as well the required tooth clearance can be found in the installation instructions. If necessary, all necessary support and adjustment tools for installation can be delivered as an option. The maintenance inspection typically covers assessment of the load carrying pattern, checking of the lubrication system, vibration measurement of the pinion bearings, measurement of the temperature prole across the tooth width, and documentation of the condition of the anks. Written documentation includes photos of tooth anks, which facilitate detection of changes in the girth gear condition by comparing and analyzing earlier inspection documents.

Picture 3. Infrared photo of a running girth gear, load carrying pattern photo  11

COMPLETE DRIVE PACKAGE

Girth gear is typically part of drum drive delivery which consist steel foundation, main drive, pinion, girth gear, xing elements and girth gear cover. Depend ing on the application emergency drives, indexing drives, couplings, clutches and brakes can be also part of the delivery scope.

KUMERA DRIVES OY FI-11100 Riihimki FINLAND Tel.: +358 20 755 4200 Fax: +358 20 755 4220 E-mail: drives@kumera.com www.kumera.com

Vammalan Kirjapaino Oy 2007