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Grinding Mill Ring Gears
Ring Gear for a 1250 HP Ball Mill
ECRS engineers were contacted when a crack was discovered in the rim of the gear between teeth # 67 & 68 during a routine maintenance inspection. The crack completely severed the rim along the line of the root of the tooth.
fea analysis
Finite Element Analysis was used in the repair design for this
gear. A model was run with the crack present and no repair.
These results are on the left. The model on the right also possesses
the crack but has the reinforcement plates installed on the inside.
You can see that these plates greatly reduced the stresses in this area.
(click to enlarge)
(click to enlarge)
repair procedures performed
Based on the analysis performed and our previous experience
in repairing cracks of this type we concluded that the crack can be
repaired by the installation of metalocks and
metalace in the crack plane. Below is a picture of the crack
before and after repair as seen from the inside. The holes you
see are for the mounting of the reinforcement plates.
reinforcement installed
Once the metalocks and metalace were
installed, additional reinforcement would be provided by the installation
of two pieces of 1" thick plate that would be bolted to the back
side of the rim on either side of the crack and then welded together.
This provides the gear with more cross-sectional area at the crack plane.
These plates are shown mounted below. They have not yet been welded
together.
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