DESIGNING LARGE GEAR WHEELS
BY THE FINITE-ELEMENT METHOD
AND DYNAMIC BEHAVIOUR ANALYSIS OF A CEMENT MILL.

GEAR WHEELS
We have designed and manufactured hundreds of electrowelded gears since 1969; lots of them have replaced the traditional cast-steel gears. Gears are produced by using our exclusive process, wich covers all steps from design to final testing.
Years of experience and the most advanced design technologies, such as the finite-element method, allow us to offer our customers the most efficient products in terms of performance and reliability.
The advantage of electrowelded gears is that they feature a U.S. inspected, fully homogeneous toothed ring in H&T alloyed steel.
Maximum performance and top reliability are achieved by coupling the electrowelded gears to our self-aligning pinion.

PRATICAL TESTS AND CALCULATION BY
THE FINITE ELEMENT METHOD
For over twenty years our engineering department has collected data on behaviour and performance of the components of dozens of cement mills in the 1000 to 3600 kW range. Vibration readings have been taken on main moving parts and their relevant supporting structures; in addition, the status of analyzed elements and any problem arising have been recorded. Such readings have been repeatedly taken at preset intervals so as to create a comprehensive data base.
Recently, we set up powerful design workstations and installed dedicated software packages for the finite-element method calculation.
By using these packages, we can analyze the critical components of machines of our own design as well as other machines.
In particular, we find checks and results of mill head analyses to be especially useful and interesting. The results of our design and checking techniques led us to collaborate closely with universities and laboratories, wich can effectively support us in making our data bank available to our customers. In the cement industry, and especially as concerns the milling area, we can supply information and advice to assist in pre and post commisioning stages, and prevent or solve any problem arising from the support structures and rotating parts.

DYNAMIC BEHAVIOUR OF MILLS AND SIMILAR MACHINES.
Once all the structural and operational data of the components of the system are known, we can analyze resonance phenomena and the resulting dynamic load of cement mills, to prevent the onset of conditions that could endager the system. All those in the business know that this occurrence will affect gears: often abnormal tooth wear occurs for wich no logical cause can be found.
Large electrowelded gears used in various industries: cement mill drives, sugar cane mill drives, steel mill mixer drives and cement kiln drives.
Finish turning of an electrowelded gear, O.D.= 6.500 mm. Non-destructive tests on an electrowelded half-gear.
Ring of gear wheel in H&T alloyed steel during preliminary welding. Final cutting of a 7.300 mm. dia. gear on our gear hobber, wich can cut gears of 10.000 mm max. diameter and 1.000 mm max. face width. Gear teeth inspection by electronic equipment on the hobber direct.

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