Large Fabricated Spur Gears for Mills, Kilns, and Heavy Machinery
Product Description
Yile Machinery is your expert partner for the manufacture of large-module, heavy-duty spur gears. We specialize in producing custom fabricated and split gears that serve as the primary drive components for the world's most demanding industrial equipment. When your ball mill, SAG mill, or rotary kiln requires a replacement gear, trust our expertise to deliver a durable, precision-engineered solution that minimizes downtime.
The Advantage of Fabricated Gear Construction
For gears of extreme diameter, fabricated construction offers superior performance and value. This process involves welding a high-strength forged steel gear rim to a structural steel web and hub.
Optimized Materials: We use a high-hardness, wear-resistant forged alloy steel (e.g., 42CrMo4 / AISI 4140) for the toothed rim and a tough, highly weldable structural steel for the body.
Cost-Effective for Large Diameters: This method is more economical than attempting to cast or forge a monolithic gear of this immense size.
Inherent Structural Integrity: Our certified welding procedures and post-weld stress relieving ensure a robust, stable component ready for decades of service.
Our Manufacturing Process: Engineering on a Massive Scale
Material Sourcing & Prep: We begin with a certified forged ring for the gear rim and high-quality steel plate for the web and hub.
Fabrication & Welding: The components are expertly assembled and welded according to stringent procedures. All critical welds undergo Non-Destructive Testing (NDT) to guarantee they are free of defects.
Post-Weld Stress Relieving (PWSR): The entire welded gear is heat-treated in a large furnace to relieve all internal stresses, ensuring dimensional stability during final machining and operation.
Massive-Scale Machining: The gear is machined on our large-capacity Vertical Turret Lathes (VTLs) to achieve precise diameters and parallelism.
Precision Gear Cutting: The teeth are cut using specialized CNC gear hobbing or milling machines capable of handling large diameters and heavy-pitch teeth.
Optional Tooth Hardening: For maximum wear life, the gear teeth can be induction or flame hardened to achieve a high surface hardness while maintaining a ductile core.
Split Gear Design for Simplified Installation
To simplify logistics and on-site installation, we can manufacture your large spur gear in two or four segments (Split Gear Design) . This allows for replacement without having to remove the main shaft or drum, dramatically reducing installation time and shutdown costs. The segments are precision-machined with mating faces for a rigid and seamless assembly.
Applications for Heavy-Duty Spur Gears
We provide critical replacement gears for:
Mining: Ball Mills, SAG Mills, Rod Mills
Cement: Rotary Kilns, Grinding Mills, Crushers
Sugar Processing: Cane Crushing Mill Drives
Power Generation: Coal Pulverizers
Other: Large Winch Drives, Dredge Cutters, Steel Mill Equipment
Get a Quote for Your Large Gear Replacement
Your primary equipment is your business. Contact us with your specifications or inquire about reverse engineering a failed component. We specialize in getting your operation back online.