The new machine joins a wide array of large machinery and equipment capable of manufacturing and refurbishing large components and assemblies.
Harcliff Mining Services has added a Kapp Niles CNC gear grinder to their machining capabilities with their newly installed Kapp Niles ZP 24 gear grinder. The Kapp Niles ZP 24 will allow Harcliff Mining Services to grind larger gears and other components such as pinions and gearbox internals that are manufactured from hardened or case-hardened alloy steel forgings and with much higher tolerance, and increased speed, expanding their services to their customers throughout the mining, mineral and pyro processing industries, energy, oil gas, and prototyping sectors.
“To continue our commitment to providing clients with the quality and reliability they deserve, we’ve increased our gear-grinding capacity by adding the massive Kapp Niles gear profile grinding machine ZP 24. This machine in combination with our other grinders enables us to produce in-house the finest quality gears possible in the widest spectrum of sizes and shapes. A major investment for our company, this new 2.4m gear grinder is a monster of a machine,” said Graeme Kneale, a director at Harcliff Mining Services.
Harcliff Mining Services has recently installed a Kapp Niles gear grinder, capable of machining high precision gears up to Ø2.4m. The machine was supplied by Retecon
“With a base weighing 21.5 tons and access to the working area via a ladder and a gantry you know the machine is big.”
“It’s impossible to overemphasise the importance of quality finished gears to the performance of an industrial gearbox. Time and time again, we’ve been called to repair gearboxes that have failed because of a minute flaw in a gear. Gear grinding enables us to avoid such flaws and provide the highest quality gears.”
“Gear grinding gives a more accurate tooth finish than gear cutting. In addition, due to their specific gear geometry, ground gears offer greater meshing effectiveness and stable operation than hobbed gears. They can also manage greater loads. For these reasons, ground gears are essential in equipment that requires high performance.”
“All of this is but another way of saying that we continue to expand our resources to assure that we’re offering you gearbox repair and manufacturing that not only meets your expectations but exceeds them.”
The Kapp Niles ZP 24 will allow Harcliff Mining Services to grind larger gears and other components such as pinions and gearbox internals that are manufactured from hardened or case-hardened alloy steel forgings and with much higher tolerance, and increased speed, expanding their services to their customers throughout the mining, mineral and pyro processing industries, energy, oil gas, and prototyping sectors
Machine concept
“The machine concept stands for maximum workpiece quality, flexibility and a long service life. The basic machines are equipped with a dresser, integrated measuring device, balancing unit and comprehensive software. The machines feature generously dimensioned rotary tables with electrical direct drive and large rotary table bores. Hydrostatic bearings and guides allow for precise positioning, excellent load capacity and a virtually unlimited service life. Due to state-of-the-art drive and control technology, even the most challenging applications can still be machined using 5-axis interpolation. All machines of the ZP series can be equipped with internal grinding attachments. Different spindle variants are available for grinding external gears.”
The company has a wide array of large machinery and equipment capable of manufacturing and refurbishing large components and assemblies up to Ø6.3m on their CNC vertical boring mill with milling head and live tooling
Harcliff Mining Services provides a comprehensive range of services for the design, manufacture, repair and installation of girth gears and pinions for use in applications including grinding mills, rotary kilns, dryers and scrubbers. In addition, the company has a dedicated works facility for industrial gearbox rebuilds and refurbishments and the production of drop-in replacements for mill drives and planetary units. The installation and commissioning of new or refurbished products is conducted by a highly experienced team of field service specialists.
Design
Design capabilities are not confined exclusively to the manufacture of new products and extend to the modification and improvement of existing gear assemblies. Amendments to gear tooth geometry and
judicious material selection increase flank durability and root strength service factors, while ensuring fitment compatibility with the original gear unit or set.
Harcliff Mining Services have recently installed another large centre lathe. They are capable of machining lengths up to 6m
An industrial gearbox in the workshop
All calculations are performed in accordance with the latest American Gear Manufacturers Association (AGMA) standards and are subjected to finite element analysis to identify potential stress areas. Harcliff Mining Services employs the latest in gear calculation software, including KISSsoft and Inventor modelling, both essential tools in the design process.
Materials
Girth gears are produced from ASTM A 148 cast steel, grades CrMo or CrNiMo alloy steels heat treated up to 320BHN.
Pinions are produced from CrNiMo through hardened alloy steel to 400BHN or 17CrNiMo6/18CrNiMo8/EN36B case carburised and hardened to 55-60HRC.
Manufacturing
Girth gears are manufactured from carbon and alloy steel castings with a capacity of up to 150 tons or Ø12.5m per gear set.
Pinions and gearbox internals are manufactured from hardened or case-hardened alloy steel forgings
Gear tooth and root areas are subjected to grinding with the latest generation Klingelnberg Höfler profile grinding technology, ensuring a high degree of accuracy in gear manufacture.
An in-board testing head enables the production of gear quality inspection graphs to verify tooth profile, lead, pitch, run out and span values and deviations.
Four 40 module pinions, 4.7m in length with a 1.1m gear face width
A large kiln girth gear
“We have the ability to manufacture gears to submicron tolerance. This level of precision is crucial because a precisely manufactured gear performs better. A tighter tolerance and more accurate fit mean less noise and less vibration, which can cause other components to fail. Beyond producing less noise and vibration, a precisely manufactured gear will last longer. It won’t prematurely fail, and it will be able to handle more torque – both are critical aspects for machinery that must meet the extreme demands. We have so much control over the entire process, from raw material procurement to finished product, that we can significantly reduce lead time and pricing, and no one can beat our quality,” concluded Kneale.
For further details contact Harcliff Mining Services on TEL: 011 392 1714/6 or visit www.harcliff.co.za
