GEARING

DESIGN REFURBISHMENTMANUFACTURE INSTALLATION

GEARINGGIRTH GEARS . PINIONS . GEARBOX REBUILDS

GIRTH GEARS AND PINIONSOur ServicesHARCLIFF 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, it 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.

DesignDesign 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.

All calculations are performed in accordance with the latest American Gear Manufacturers Association (AGMA) standards and subjected to finite element analysis to identify potential stress areas. Harcliff Mining Services employs the latest in gear calculation software, including KISSoft and Inventor modelling, both essential tools in the design process.

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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 gear box 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• 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.

Girth Gears• Steel castings with a capacity of up to 150 tons per gear set• Ladle refining is an important feature of the casting process as it removes impurities from the final cast and

helps to accurately control chemical compositions• We employ the world’s largest liquid quenching facilities to ensure uniform hardness throughout the

component• Machining and gear hobbing up to Ø12.5mm, 1,200mm face widths• Max module = 42 mod.

Pinions• A vacuum degassing furnace is used prior to casting ingots to ensure forgings have high-quality mechanical

properties• Gear grinding is conducted to a minimum accuracy of AGMA Q12 class or higher.

GEARING

• Full refurbishment services to all makes of gear units, including test running• In-house design and manufacture of ‘drop-in’ mill drives • Modernise existing gearboxes, including improvements to lubrication systems, gear materials and tooth

designs• All rebuilds include on-site installation• Condition monitoring is one of our specialities.

GEARBOX REBUILDS

GEARING

HARCLIFF MINING SERVICES has invested in a Höfler Rapid 2000 cylindrical gear grinding machine manufactured by the Klingelnberg Group, one of the world’s leading producers of precision gear grinding and measuring equipment.

The grinder produced by Klingelnberg’s manufacturing facility in Ettlingen, Germany, has enabled HARCLIFF to supply gears of the highest quality to both domestic and export markets. Precision gear components and pinions are manufactured to standards well above traditional hobbing and gear shaping manufacturing methods and in a wide range of dimensions. These can extend up to 2m in diameter and 14 tons in weight with a module range of 1-50.

Another gain from the use of this advanced technology is that manufacturing cycle times are significantly shorter, enabling an even faster response to meet customer needs.

Accuracy Classes Achievable:• AGMA Q12 and higher• Super-fine surface finish (<0,8Ra)

WORLD-CLASS GEAR GRINDING TECHNOLOGY

HARCLIFF MINING SERVICES

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GEARING

HARCLIFF MINING SERVICES is an acknowledged global specialist in the design, manufacture and refurbishment of new and existing equipment for the mining, minerals processing, pyroprocessing, cement, power generation and petrochemical sectors. Aftermarket support, installation and relocation are crucial aspects of the company’s service offering and are conducted by highly experienced teams with years of expertise in the field.

HARCLIFF MINING SERVICES manufactures and refurbishes:

• Grinding mills and components• Rotary scrubbers• Gearing and gear units• Electric rope shovel and hydraulic shovel spares• Kiln and dryer components• Wear parts • Industrial gearbox rebuilds and drop-in

replacement gear units• Crusher repairs and parts.

61/62 Fleming Road, Meadowdale, Germiston, 1614

PO Box 2019, Bedfordview, 2008, South Africa

Telephone: +27 11 392 1714/6info@harcliff.co.za