our full brochure [LOW RESOLUTION]

Since 1969 Hofmann Engineering has p rovided specialist engineering services t o Australia’s industry leaders.

Quality Assurance certification by Lloyds co mplements our total quality culture.

Ou r commitment to continuous quality-improvement touches every aspect of o u r products, services and customer su pport.

KEY CAPABILITIESGEAR MANUFACTURING

PRECISION & HEAVY MACHINING

HEAT TREATMENT

ENGINEERING & MINING EQUIPMENT

REPAIRS & MAINTENANCE

SPECIALIST TRANSMISSION REPAIRS

RESEARCH & DEVELOPMENT

SPECIALIST TOOLS & EQUIPMENT

PORTABLE MACHINE TOOLS

REPLACEMENT PARTS

ON-SITE MACHINING

DEFENCE PROJECTS

METROLOGY SERVICE

DESIGN & CONSULTING SERVICES

FABRICATION & WELDING

FIELD SERVICE

AEROSPACE

LEADERS IN WORLD CLASS PRECISION ENGINEERING

INTRODUCTION

AUSTRALIAN LEADERSHIP IN WORLD CLASS PRECISION ENGINEERING

25m high machine shop suitable for 200

tonne lifts.

Hofmann Engineering, founded by John and ErichHofmann in 1969 is a successful family owned and runengineering business. The precision and expertise thatHofmann Engineering offers in the manufacturing andrefurbishing of precision mining equipment is soughtfrom companies both locally and internationally.

Stable cash flow management has enabled HofmannEngineering to grow into one of the largest privatelyowned engineering facilities in Australia, employingover 600 people world wide. In 2003 leadership ofHofmann Engineering was passed to the secondgeneration with John’s son Erich J Hofmann nowleading the company in their continued pursuit ofexcellence.

CONTENTS2 INTRODUCTION & CONTENTS 46 SHOVEL - SWING GEARS3 GLOBAL PREMISES 47 SHOVEL - PLANETARY GEAR BOXES5 GEAR MANUFACTURE 49 HYDRAULIC EXCAVATOR – REPLACEMENT PARTS7 BEVEL GEARS & WORM WHEELS 51 SLEW BEARINGS9 DESIGN INSPECTION MEASURMENT METALLURGY 53 TRACK PADS (4 pages)

ULTRASONICS 57 MINING TRUCK PARTS

11 MILLS & KILNS 59 EXCAVATORS & RECLAIMERS

13 GRINDING MILL SHELLS & HEADS 61 RAIL15 SELF ALIGNING DRIVES 63 HOFMANN PORTABLE MACHINE TOOLS17 MILL & KILN PINIONS 65 HOFNUTS19 LARGE MILL & KILN GEARS 67 VALVE AND PUMP21 FORGED STEEL FABRICATED GEARS 69 CRUSHER REPAIRS & SERVICE AND REPLACEMENT PARTS23 OPEN GEAR RECONDITIONING PROCEDURE 71 HPGR (HIGH PRESSURE GRINDING ROLLS)

25 GEARBOX RANGE 73 UNDERGROUND MINING

27 GEARBOX REBUILD DIVISION 74 VIBRATING SCREENS29 ONSITE SERVICE 75 DISC VACUUM FILTERS31 KILN SERVICES 77 DEFENCE33 SUGAR MILLS 79 AEROSPACE35 OIL & GAS 81 CUTTING TOOLS37 WIND TURBINE GEARBOXES 83 FOOD PACKAGING39 ENERGY POWER STATIONS 85 PRESS SHOP41 DRAGLINE – REPLACEMENT PARTS (4 pages) 87 WORLD WIDE REPRESENTATIVES & HEAD OFFICE LOCATION45 SHOVEL – REPLACEMENT PARTS

Hofmann Engineering’s Directors. Clockwise from left:

Stephan Kirsch, Erich J Hofmann, Erich F Hofmann, Leighton White

& John Hofmann.

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HOFMANN BENDIGO

Specialising in:

• Heavy Fabrication• Gearbox Manufacture & Overhaul• Heavy Machining• Heat Treatment• Onsite Services

Hofmann Engineering now boasts three facilities(Bendigo, Melbourne & Newcastle) on the east coastof Australia as well as a facility in Canada, NorthAmerica and Chile & Peru in South America.

HOFMANN METALTEC

Specialising in:

• Aerospace Tooling• Food Packaging• Cutting Tools • Pressing• Precision Tooling

25 Bushmaster CourtNorth Bendigo, VICTORIA 3550AUSTRALIAPhone: +61-3-5440 7400

292 Bay RdCHELTENHAM VICTORIA 3192AUSTRALIAPhone: +61-3-8585 1800

GLOBAL PREMISES

AustraliaCanada

USAChilePeruIndiaChina

Agents and Representatives

Worldwide

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[email protected]

Telephone:Facsimile:Net: Email:

HOFMANN ENGINEERING PTY LTD

3 ALICE STREET, BASSENDEAN, PERTH, WESTERN AUSTRALIA 6054

HOFMANN CANADA330 Pinebush RdCAMBRIDGE ONTARIOCANADAEmail: [email protected]: +1-903-391-0960

GLOBAL PREMISES

HOFMANN SUDAMÉRICA LTD

Av. Pedro Aguirre Cerda 5802ANTOFAGASTA CHILE Mobile: +56-9-8294 7851 Office: +56-55-441760

Hofmann Canada still retains their land and building ownership and maintains their relationship with SKF (current tenant) for special Projects.

The South American operation offers General machining and Gearbox rebuild facilities and parts storage and sales.

Specialising in:• Onsite Machining and installation service• Precision Gearbox Rebuild Centre• Shovel – Truck – Crusher – Mill Components

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Telephone:Facsimile:Internet: Email:

HOFMANN ENGINEERING PTY LTD3 ALICE STREET, BASSENDEAN, PERTH, WESTERN AUSTRALIA 6054

HOFMANN INDIA

16, 5th Cross, Ramakrishna Nagar Nandini LayoutBANGALOREPhone : +91-80-2319 6155Mo bile: +91-99-0008 5921

HOFMANN USA

147 FM 27 WestFa irfield Texas 75840USA (Note: This is a home office)Phone : +1-903-391-0960

HOFMANN PERU

Phone : +51-54-275644Pe [email protected]

HOFMANN CHINA

(+86) 18258782883 J [email protected]@Hofmannengineering.com

HOFMANN NEWCASTLE44 Broadmeadow RoadBROADMEADOW NSW 2292AUSTRALIASpecialising in:• Heavy Engineering to 14m dia.• Gearing to 12 dia.• Gearbox rebuilds, underground

mining, mobile mining equipment & replacement parts .

GEAR

MANUFACTURE

DESIGN AND CONSULTING SERVICES.Analyse and solve your particular gear or gearbox problem using the latest gear design sof tware to either D.I.N., A.G.M.A., B.S. or Australian Gear Standards.• Industrial Gearbox and gear design.• Onsite gear inspection and consultancy • service.• Computer aided draf ting.

TURNINGA range of lathes both conventional and computer (CNC) controlled for turning of gear blanks and shafts to 35,000mm long.• Final grinding of shafts to 8,000mm long.

FABRICATION.Complete w elding and fabrication facilities to 200 tonnes.• Fabricated gearbox casings and gears.• Rebanding w orn gears via welding ring forging • to original hub.• Qualified w elders with accredited welding • procedures.

HORIZONTAL BORING.A range of both conventional and computer controlled (CNC) borers are available to 18,000mm x 5000mm.• Machining of large gearbox housings.

1

68,000 KG DREDGE BUCKET WHEEL DRIVE GEARBOXThis gearbox operates 20m underwater for dredging mineral sands. The technical advancement of incorporating case hardened gearing throughout helped us win the order against some of the world’s leading gearbox manufacturers.

2

43

ALL MANUFACTURED UNDER ONE ROOF

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GEAR HOBBINGManufacture of high accuracy gears and w orm w heels.• Carbide skiving of case hardened gears.• Computer (CNC) controlled accuracy • (15000mm dia).

LARGE GEAR CUTTINGInternal and external gearing to 15000mm dia. x 2500mm face.• Re-cutting of w orn girth gears and • slew rings.• Full involute form carbide finish cutting • of gears.

HEAT TREATMENTOne of Australia’s largest specialised heat treatment facilities encompassing:• Oil quench & tempering, stress relieving.• Gas carburisingvia pit furnace or f luid • bed 1800mm dia. x 5000mm.• Tool steel heat treatment.

INDUCTION HARDENINGTooth by tooth full contour induction hardening to produce a hard w ear resistant case up to 20mm deep supported by a tough impact resistant core.• Mill pinions, slew bearing races.• Traction gears.• Spin hardening of pins and splines.• 15,000mm dia. x 2500mm face.

METALURGICAL LABORATORYAn extensively equipped laboratory to facilitate both failure analysis and the inspection of test pieces heat treated w ith each and every furnace charge.

GEAR GRINDINGAustralia’s most comprehensively equipped gear grinding facilities w ith 4Höfler form grinders.• 2500mm dia. x 1500mm face x 40Mn.• Completely climate controlled area.• Prof ile and lead modif ication facilities • (tip/root relief and crow ning).• CNC Form grinding of both internal and • external gearing to 2500mm dia.

GEAR INSPECTION LABORATORYA climate controlled inspection area for the verification of all gear geometry parameters.• Lead involute and pitch inspection.• Calibrated inspection machines.• Crack detection.

GEAR BOX TEST BED FACILITY 2MW FULL LOADEvery gearbox w e manufacture or overhaul is test run and a detailed test run report compiled.• Partial load testing.• Back to back full load gearbox test • capability.• DC stepless drive system.

CO-ORDINATE MEASURING MACHINE3D machine w ith lead, involute and pitch software to enable the complete inspection of large gearing.• Climate controlled laboratory • environment.• Gears to 15,000mm dia. x 2500mm face.• Gearbox housings and complex shapes.

ALL MANUFACTURED UNDER ONE ROOF

765

1098

12 1311

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BEVEL GEARSSPIRAL

HELICALSTRAIGHT

Also

WORM WHEELS&

WORMSHAFTS

CAPACITY:8 off 5-axis machines

Size ≤ ф4m• BEVEL GEARING • WORM GEARING •

DESIGNED OR REVERSE ENGINEERING & MANUFACTURED UNDER ONE ROOF

DESIGNUsing state-of-the-art engineeringcalculation programs in the hands of talentedengineers, a 3D model of your bevel gearcan be produced to DIN, AGMA or Gleasonstandards from the outputs. For replacementgears, the model of the existing design canbe acquired from a CMM and modified tosolve the problem which caused it to fail.Tooth modification can also be optimised togive quiet running gears.

INSPECTIONHofmann Engineering prides itself on producing superior quality products. The onlyway to ensure that this is achieved is by imposing a highly accurate inspectionprocess which the Spiral, Helical or Straight Bevel Gearing along with the WormGearing must pass before they can be released from the factory. All these types ofGearing are inspected on our two large CMM’s or the portable CMM arm.

CUTTINGHofmann Engineering currently has 8 new 5-axis machines for cutting spiral, helical and straight bevel gearsalong with worm wheels. It also has a unique software, crafted exclusively to obtain the optimised CAM programto machine the profile of spiral, helical and straight bevel gears plus worm wheels.

WORM MESH CONTACT INSPECTIONWorm wheel and wormshaftbeing inspected to confirm contact accuracy.

WORM GRINDINGWormshafts being ground on one of our Hofler form grinders. After grinding the accuracy is preliminary checked prior to final inspection on the CMM

HEAT TREATMENTOver the years, Hofmann Engineering has developed the technology toheat treat many different types of gears. This technology can also beapplied to spiral, helical, straight bevel gears and wormshafts to improvetheir performance and li fe. Hofmann Engineering is capable of casecarburising to a diameter of 1.87m, and full contour, tooth-by-toothinduction hardening to a diameter of 4m. Once the gears have been heat-treated, they can be hard cut to DIN 3.

TESTINGHofmann Engineering can testtheir spiral bevel gears in thegearbox on their load test cell toensure that the gearbox will bewithin the noise specificationsrequired by the customer.

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METROLOGYINSPECTION

DESIGNMETALLURGY

SPECTROANALYSISULTRASONICS

ONSITE INSITU INSPECTION Hofmann Engineering continually improve quality and expand their library of product improved parts by pushing the frontline of inspection technology.

The tw o 6-axis Portable Co-ordinate Measuring Machines (PCMM) run a number of different softwares for general inspection and also a unique gear inspection sof tware and achieve an accuracy of 20µm (≈0.001”).

A state-of-the-art Laser Scanner attaches to the head of our PCMM’s, and produces a laser scanned point cloud from w hich a model can be created.

The tw o Laser Trackers have up to a 320m radial measuring volume producing micron accuracy on large parts such as mill heads, gearbox casings and slew gears.

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ENGINEERING DESIGN• 2D and 3D CAD to produce

manufacturing draw ings.• 5-axis CAM to program

machining.We design all types of components including:• Aerospace tooling• HPGR’s• TrackpadsPrograms: AutoCAD, Solidw orks, Unigraphics NX CAD/CAM, PEPS, Catia v5, CADDS, and Pro_E.

GEAR DESIGN & ANALYSIS Programs: KISSsof t and TBK.Gear tooth optimisation; contact pattern and modif ication analysis to produce quiet running gearing.Shaft and bearing calculations.Typical design components: spur, helical and double helical gears and splines; planetary gear trains; straight, skew , spiral, zerol and hypoid bevel gearing; w orm gearing; special tooling; and f lexible couplings.

FINITE ELEMENT ANALYSIS (FEA)Static and dynamic FEA simulations can be performed.Special gear tooth FEA programs to analyse cracks in cast gearing.Typical applications: gearbox casings; Hofmann re-designed components; cast gearing; rope drums; and eccentrics.

METALLURGYComplete metallurgical lab for:• quality control of heat treatment

processes;• metallurgical failure analysis.Our speciality is failure analysis of gearing to AGMA and DIN standards.

SPECTROGRAPHICS ANALYSISFull chemical composition analysis of carbon and alloy steels; stainless steel; aluminium; copper; and nickel alloys.Ideal for material identif ication and Weld Procedure Specification.

ULTRASONIC NDT INSPECTIONFor quality control and defect identif ication.NATA certif ied operators.In-house and external Quality Assurance.

CMM LABORATORY INSPECTIONA state-of-the-art, climate controlled and vibrationally isolated inspection laboratory houses the f ixed CMM. With accuracy to 2µm, the CMM has the capability, software and is accredited to inspect gears to 6m diameter, pinions f rom small to large mill pinions, aerospace parts, w orm gearing, bevel gears and many other components.

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LubricationSystems

Couplings – Rubber Flex,Gear Flex & Disengaging

Inching Drives

GearReducers

MillPinions

GirthGears

Girth Gear Guards & Sealing Systems

Heads &Shells

Onsite Inspections,Installation & Machining

Bearings: White Metal/Bronze

LubricantSupply

MILLS &

KILNS

PINIONS

1 Through-Hardened.

2 Induction-Hardened.

3 Case-Carburised.

4 HofCarb Carburised.

5 Self-Aligning.

CAPACITY

• Size - 1.6m face x 6m lg.

• Hardness - to 62 HRC

• Quality - AGMA 13 (DIN 3)

GIRTH GEARS

1 SG Iron.

2 Cast Steel.

3 Austempered SG Iron.

4 Forged Fabricated.

5 Forged Fabricated Induction Hardened.

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CAPACITY 15m ( 50ft)

• Size - 2.5m face x 15m dia.

• Hardness - to 52HRC (500BHN).

• Quality - AGMA 10 (DIN 7).

SELF-ALIGNING DRIVES• Automatically maintains 100% gear

contact regardless of movement in foundations and/or driven component.

• Can use recirculating f iltered oil.• Reduced maintenance as alignment

checks and adjustments are eliminated.• Pow er to 10 000kW per gearbox.

GEARBOXES STANDARDCompletely designed and manufactured in

house using AGMA and DIN standards.• Standardrange of multi-stage drives.• Precision Case-carburised and ground

gearing to AGMA 14 for quiet reliable operation.

GEARBOXES SPECIALSSpecial Gearboxes can be designed to fit existing foundation as a direct replacement of your old drive. (Flender, Falk, Valmet etc.)• Pow er upgrades, ratio changes and

replacement parts available.• Torque-splitting gear drives.

INCHING DRIVESHofmann Engineering makes a range ofinching drives to f it to new and existing mill and kiln drives. Features include:• Planetary main reduction.• Hydraulic or electric.• Integral or separate brakes.• Disengaging couplings.

GEAR PROTECTION SYSTEMS• Continuous & intermittent grease spray

systems.• Re-circulating f iltered oil systems.• Infrared temperature monitoring systems. • Measures gear mesh temperature.• Sealing systems for girth gears and

trunnion bearings.

LUBRICANT SUPPLYHofmann Lubrication division has an agreement w ith Kluber Lubrication Germany AG to supply a range of products, directly formulated to Protect the Gearing that w e design and manufacture.

This forms an integral part of our Gear Protection Package used to improve the life of high performance gearing.

ONSITE MACHINING• Flange and Journal machining to 14m

dia.• Line boring and drilling to 3m dia x 6m L.• Grinding and linishing of kiln tyres.• Milling of keyw ays and surfaces.• Welding and heat-treatment.• Bolt tensioning.• Special purpose machinery design and

manufacture to suit your application.

ONSITE INSPECTION & CONSULTING SERVICE .• Inspection and assessment of your mill

and drive train.• Failure analysis including Engineering

and Gearing design review . Finite Element Analysis and Metallurgical Analysis.

ONSITE SERVICE• Laser alignments of drive trains.• Girth gear/pinion installation.• Reconditioning of w orn gearing using

case hardened pinions and chemical etchant.

• Trunnion bearing installation including scraping in of w hite metal bearings.

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MANUFACTURING CAPACITY: 2 Manufacturing Sites • Bassendean – Western Australia

• Bendigo - Victoria (Australia)

• Max Shell Size: Ø13.4m (44ft)• Lift Capacity: 210 tonne (231 ton) x 17m (55.7ft) under crane hook.• Vertical Rolls: 6000 tonne (6600 ton) & 4000 tonne (4400 ton). • Sub Arc Welding using tandem head inverter technology.• Machining to Ø16m (52ft) x 6m (19.7ft) x 300 tonne (330 ton) capacity

rotary table.• Floor Borers: 15.3m (50ft) x 5.0m (16ft) & 12m (39ft) x 3.9m (12.8ft).• Heat Treatment: Stress Relieving Ø14m x 4m high.• Surface Finish: Abrasive Blast / Paint Booths / Epoxy Coating, Rubber

Lining.

GRINDINGMILL SHELLS

& HEADSTo Ø44 ft

• Fabricated Steel• Solid Stainless

Steel• Stainless Steel Clad• Bimetallic Plate• Epoxy Coated• Cast Steel• Cast SG Iron

6000 TONNER VERTICAL ROLLING PRESSMax thickness 220mm

Width 3650mm

Hardness 390BHN

FABRICATIONTypical steel plate to AS3678 Grade 250,

EN S235JR, ASTM A36.

Segments prof iled to shape w ith bevelling.

Stainless Steel Clad plate available.

FABRICATIONPlate UT examination to AS 1710

Flange plate Z property tensile tested.

Welded and tested to AWS D1.1

Stainless Steel to AWS D1.6 available.

VERTICAL BORER

Bendigo:Schiess Ø9.22m x 4.45m height 200T

Schiess Ø7.0m x 3.50m height 200T

Bassendean:Schiess Ø8.75m x 2.7m height 200T

FLOOR BORER

Bendigo: INNOCENTI CNC

15.3m x 5.0m high x 1.25m Z travel.

Floor plate area 19.50m x 6.55m

CNC Rotary Table 2.5m x 2.5m x 200T

FLOOR BORER

Bassendean:WMW BP160CNC

12m x 3.9m high x 2.0m Z travel.

Floor plate area 18.0m x 6.0m

CNC Rotary Table

LARGE VERTICAL MACHINE:Bassendean & Bendigo:Floor Borer and 200T Table to machine and drill Mill Shells up to Ø15m by 7m height.

SZIM GANTRY MACHINING CENTRE:Unique boom arrangement combined w ith a rotary table w ill allow the machine to act as vertical borer and drill on the same set up. Max capacity Ø15m.

WELDING MANIPULATOR:Adjustable to accommodate head angle. Manipulator & Boom drives synchronised. 200 tonne capacity. CNC controlled for SS cladding of heads and shells

ROAD & SEA FREIGHT

HEAT TREATMENTStress Relieving Furnace Ø14m x 4m

SURFACE FINISHAbrasive blast, paint, Epoxy Coat and rubber line as required.

PACKAGINGMachined surfaces coated with rust inhibitor. Packaged and protected for road, ocean and air freight.

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AIRFREIGHT – ANTONOV TO 90T/PIECE

SELF ALIGNING DRIVES

HOFMANN SELF ALIGNING DRIVES always maintain 100% contact

automatically through all loading stages regardless of:• Mating gear axial run out.• Foundation movement and temperature expansion changes.• Deflections and load variations.

APPLICATIONS• Mills, Kilns, Dryers and Car Dumpers.• Dragline, Shovels, Winders and Slewing Drives.• Any gear drive where self aligning is required to reduce maintenance.

Case Hardened Gear couplings to transmit torque.

Hardened spherical bearings to enable self aligning motion.

MILL DRIVES TO 20,000KW• Using 2 off 10 000kW drives. • 4 off self aligning pinions drive the • girth gear. • Mechanical drive options to 34MW.

DIRECT MESH GEARBOXINCORPORATING TWIN TORQUE

SPLITTING SELF-ALIGNING PINIONS TO 10,000KW

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Qu ality Assurance a certification by Lloyds complements our total quality cu lture.


1) SAP - Self Aligning Pinions

2) SAOP - Self Aligning Overhung Pinion Drive 4) SASP - Self Aligning Single Pinion Drive

3) SATP - Self Aligning Twin Pinion DriveConventional Self Aligning Pinion with plummer block bearings.• Retrofit to existing mills and drives.• Pinion shaft is reversible.

• 4 standard sizes 18Mn, 22Mn, 25.4Mn & 30Mn that • covers the complete range to 10,000kW.• Single motor runs two self aligning, torque splitting • pinions direct meshed with the girth gear.• Reduced foundation, installation and running costs.• Oil re-circulating system for gearbox and girth gear.

Self-aligning pinion mounts directly to the output shaft and is integral with the main gearbox.• Reduced foundation and installation costs.• No low speed coupling or plummer bearings.• Split lube system between gearbox and open gearing is • now possible.

Self-aligning overhung pinion mounts directly to output shaft main gearbox.• Lowest foundation and installation costs.• No low speed coupling or plummer bearings.• Split lube system between gearbox and open gearing is • now possible.

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PINIONS

1. Through-Hardened.

2. Induction-Hardened.

3. Case-Carburised.

4. HofCarb Carburised.

5. Self-Aligning.

CAPACITY

• Size - 1.6m face x 6m lg.

• Hardness - to 62 HRC.

• Quality - AGMA14 (DIN 4).

MILL&

KILN PINIONS

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0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

1 2 3 4 5

PINION TYPE

Pinion Rating Comparison Same Size But Different Hardness And Quality

SOFT INDUCTION HARD & CARBURISED & HOFCARB & CARBURISED &

QUENCH & TEMP GROUND GROUND GROUND SELF ALIGNING

Material AISI 4340

M

a

x AISI 4340

M

a

x Din 17CrNiMo6

M

a

x Din 17CrNiMo6

M

a

x Din 17CrNiMo6

M

a

x

Heat Treatment Quench & Temp Induction Hardened Gas Carburised Gas Carburised Gas Carburised

Hardness 290 BHN 420 BHN Core = 300 BHN 400 BHN Core =400 BHN 420 BHN Core =400 BHN 420 BHN Core =400 BHN 420 BHN

Case = 56 RC 60RC Cas e = 60 RC 62RC Case = 60 RC 62RC Case = 60 RC 62RC

Depth = 7 mm 10mm Depth = 5 mm 6mm Depth = 5 mm 6mm Depth = 5 mm 6mm

Quality AGMA 10 (DIN 8) 11 AGMA 12 (DIN 6) 15 AGMA 12 (DIN 6) 15 AGMA 12 (D IN 6) 15 AGMA 12 (DIN 6) 15

Machining Hobbed Ground Ground Ground Ground

Pictures depict typical

pinion types being

manufactured by

Hofmann Engineering

Example

Power De tails Power (kW) 3500

Speed (RPM) 188

Geometry Module Mn 25.4 Mn max = 100 Mn max = 32 Mn max = 32 Mn max = 32 Mn max =32

P ressure Ang 25° max = 45 ° max = 45 ° m ax = 4 5 ° max = 45 ° max = 45 °

Helix Angle 0 max = 45 ° max = 45 ° m ax = 4 5 ° max = 45 ° max = 45 °

Nos Teeth Z 25 Z max = 600 Z m ax = 6 00 Z m ax = 6 00 Z max = 600 Z max = 600

Face Widt h F 700 F max = 25 00 mm F max = 1200 m m F max = 1200 m m F max = 1200 mm F max = 120 0 mm

Overa ll Length L 320 0 L max = 12000 mm L m ax = 6 000 mm L m ax = 3 700 mm L max = 3700 mm L max = 3700 m m

Out side Dia da 701 da max = 8000 mm da m ax = 3 000 mm da m ax = 1900 mm da max = 1900 m m da max = 1900 m m

W eight (Kg) W 400 0 W max = 100 tonne W max = 20 ton ne W max = 20 ton ne W m ax = 2 0 to nne W m ax = 2 0 t onne

% Price 100% 120% 140% 140% 160%

De livery 18 weeks 21 Weeks 21 We eks 21 Weeks 24 We eks

AGMA 6004

Pitting Csf 1.21 2.77 3.53 4.27 4.72

Strength KsF 2.05 2.48 2.76 2.9 3.2

INDUCTION HARD &

GROUND

CARBURISED &

GROUND

HOFCARB &

GROUND

CARBURISED &

SELF ALIGNINGSOFT

QUENCH & TEMP

Large Pinion Rating Comparison

Strength Ksf

Pitting Csf

LARGE MILL&

KILN GEARS

TO 15M

GIRTH GEARS

1. SG Iron.

2. Cast Steel.

3. Austempered SG Iron.

4. Forged Fabricated.

5. Forged Fabricated Induction

Hardened.

CAPACITY

• Size -15m (50ft).

- 2.5m face x 15m dia.

• Hardness - to 52HRC (500BHN).

• Quality - AGMA 10 (DIN 5).

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SG IRON CAST STEEL AUSTUF FORGING FABRICATED FORGING FABRICATED

NORMALISED NORMALISED AUSTEMPERED QUENCH & TEMP CONTOUR INDUCTION

INDIVIDUAL RISER FULL RING RISER SG IRON HARDENED

Material AS 1831-700-2

M

a

x AISI 4140

M

a

x AS 1831-700-2

M

a

x HofMod

M

a

x HofMod

M

a

xHeat Treatment Normalised Normalised Aus temperded Quench & Temp Inductio Hard

Hardnes s 280 BHN 330 BHN 280 BHN 360 BHN 380 BHN 400BHN 300 BHN 380 BHN Core =280 BHN 300 BHN

Case = 50 HRC 58 HRCDepth = 5 mm 10mm

Quality AGMA 10 (DIN 8) 10 A GMA 10 (DIN 8) 10 AGMA 10 (DIN 8) 10 A GMA 10 (DIN 8) 10 AGMA 10 (DIN 8 ) 10

Machining Hobbed Hobbed Hobbed Hobbed Hob / Hardcut

Example

Power Details Power (kW) 4500

G Speed (RPM) 14

Geometry Hofmann Hobbing (HSS) Skiving (Carbide Hob) Form Milling (Carbide) Finger Milling + Double Helic alExample Maximum Cap External Internal Gear External Internal Gear Exte rna l Internal Gear External Internal Gear

M odule Mn 2 5.4 Max Module 50 Mn 25 Mn 50 Mn 25 Mn 100 Mn 60 Mn 100 Mn 60 Mn Pressure An g 2 5° Max Press Ang 4 5° 45° 4 5° 4 5° 45 ° 45° 45 ° 45°

He lix Angle 5° 3 0' Max Helix Ang 4 5° 45° 4 5° 4 5° 45 ° 45° 45 ° 45°

Nos T eeth Z 282 Max No Tee th 700mm 700 700 700 700 700 700 700 Face Width F 860 Max Face Width 2500mm 500 2500 500 2500 600 2500 600 Outside Dia da 7247 Max Outside Dia 14000mm 14000mm 14000mm 14000mm 14000mm 14000mm 14000mm 14000mm Weight (t ) W 50 Max Weight 130 t 130 t 130 t 130 t 130 t 130 t 130 t 130 t

% Price Example 100% 130% 105% 125% 135%

Delivery Example 32 weeks 39 Weeks 34 Weeks 29 Weeks 31 Weeks

AGMA 6004 - F88 Pitting Csf 1.64 1.62 3.07 1.85 3.26

Strength KsF 1.9 2.00 2.24 2.35 2.61

MECH TESTS

Elongation (%) 3 6 3 16 16 Izod (J) 3 15 10 60 60

1.64 1.62

3.07

1.85

3.26

1.90 2.002.24 2.35

2.61

0

0.5

1

1.5

2

2.5

3

3.5

1 2 3 4 5

GEAR TYPE

Pitting Csf

Strength KsF

SA

FE

TY

FA

CT

OR

AG

MA

600

4 -F

88

FABRICATED FORGING QUENCH &

TEMPER

CAST STEELINDIVID RISERSNORMALISED

AUSTUFAUSTEMPERED SG IRON

FABRICATEDFORGING INDUCT HARD

SG IRONINDIVIDUAL RISER

NORMALISED

MECHANICAL TEST RESULTS

0

10

20

30

40

50

60

70

1 2 3 4 5

GEAR TYPE

Elongation(%)

Izod (J)

EL

ON

GA

TIO

N %

IZO

D J

CAST STEEL RING RISER NORMALISED

AUSTUFAUSTEMPERED SG IRON

FABRICATEDFORGING INDUCT HARD

SG IRONINDIVIDUAL RISER

NORMALISED

FABRICATEDFORGING QUENCH

& TEMPER

GIRTH GEAR RATING COMPARISON SAME SIZE BUT DIFFERENT HARDNESS AND QUALITY

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FORGED STEELUse Forged Steel FabricatedGirth Gears to overcomeyour cast steel crackingproblems. Forged steelgives the highest crack andimpact resistance.

HOFALLOY FORGED MATERIALHofalloy 1 Forged Gear Rim Material conforms to:1) AGMA 2001 Grade 2

specification.2) Hardness 330 – 360

BHN.3) 3:1 Forging Reduction.4) Induction Hardenable.5) Site weld repairable in the

event of a catastrophic mishap.

STOCKED INSURANCE SPARE MATERIALUse one plate to suit a variety of gears On Site:1) FORGED HOFALLOY

plate can be used as an insurance spare to cover many different girth gears.

2) Reduces manufacturing lead time.

3) Lowers insurance premiums.

FORGED STEEL

FABRICATED GIRTH GEARS

CASTING defects and imperfections cause cracking and tooth breakout.

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SITE AUDITSEvaluate Girth Gears and their conditions. Determine suitable forged steel rim plate –dimensions based on pitch, face w idth & Gear diameter. Order forged rim plate based on site audit. Rim plate can be ordered to suit a variety of Gears on site.

SITE GEAR INSPECTIONS• Full Dimensional inspections done onsite.• Diameters, Lengths, Hole PCD • Full Gear inspection including:

• Pitch.• Lead.• Involute.

• Hardness testing.• Crack detection.• Material chemical analysis.

DESIGN• CAD design w ith 3D modelling to

produce accurate manufacturing draw ings.

• FEA analysis to optimise the w eld sizing to keep stress levels to a minimum.

• Gear consulting.• Gear design & rating calculating to DIN

& AGMA standards.

FORGED STEEL• Rim plate can be held in stock until

required.• One plate can be purchased to suit a

variety of Gears on individual or corporate sites.

• Once forged steel is in stock, manufacture lead time can be signif icantly reduced.

OXY CUTTING• The forged steel is marked out & oxy-cut

to w idth to suit the specific gear to be manufactured.

• Purchase of material in advance (No holding fee) allow s the spread of costs over period of time.

BENDINGThe individual lengths of plate are then rolled to the specif ic radius required for your gear.• 6000 tonne roll pressing capacity.• Unlimited length.• 250mm thick x 3700mm w ide.

.

FABRICATION• Individual segments are fabricated to the

strictest of welding and inspection procedures.

• NDT Inspection including 3rd party NATA ultrasonics.

• Full penetration submerged arc w elds on critical joints.

• Stress relieved.

MACHINING• Proof Machined.• Finished machined.• Dimensionally inspected to

internationally recognised standards.• Full gear inspection including final mesh

testing.

INSTALLATION & AlignmentsExperienced team available to Plan, Manage & install your; Girth Gears, Pinion Assemblies, Gearboxes & Inching Drives.Fully Equipped w ith all tooling, for laser Aligning, Machining, Fabrication & Mill Drive Adjustments Ready for site w ork.

8 9

5 6

1 2 3

4

7

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OPEN GEAR RECONDITIONING

PROCEDURE

1) WORN GIRTH GEARWith less than 0.5mm of involute wear.

2) WORN SOFT PINIONWith over 5mm of wear.

3) INSTALL HOFMANN CASE HARDENED PINION

4) APPLY H0FMANN PROCEDURE.1) Measure involute Wear on Gear.2) Clean and Crack detect gear using magnetic particle method.3) Install Hofmann case hardened Pinion. Case Hardness must exceed 55HRC.4) Laser align Drive Train.5) Accurately in-situ grind girth gear using the case hardened pinion as a master.6) Apply Hofmann Grafloscon A-C1 Ultra primer to pinion and gear.7) Inspect lubrication system and connect running-in lubricant Hofmann

Grafloscon B-SG00 Ultra.8) Start gear drive slowly increasing the power as the contact improves.9) Apply repair Chemical Etch Hofmann Grafloscon D-SG00 Ultra to heavy

contact areas until good contact is achieved.10) Monitor and completely document the installation procedure.

5) FINAL GEAR CONTACT 6) FINAL PINION CONTACT- 23 -

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SELECTING OPEN GEAR RECONDITIONING PROCEDURE

SELECTING GEAR RECONDITIONING PROCEDURE

Measure involute wear on gear then select reconditioning procedure.

Procedure 1: If involute wear is less than or equal to 0.5mm => In-situ grind and chemical etch utilising a Hofmann case hardened pinion.

Procedure 2: If involute wear is greater than 0.5mm => Reverse open gear.

Procedure 3: If both flanks of the gear are worn => Re- cut the open gear.

Procedure 4: If insufficient material is left to re-cut the gear => Replace the open gear.

WARNING!!Do not install a new pinion against a worn open gear unless one of the above procedures (from 1 to 4) has been performed. The new involute form on the pinion would only contact the high points of the worn open gear and this can lead to:-

View of Open Gear showing substantial involute wear

• Extreme vibration and noise.• Severe wear and pitting on both pinion and gear.• High possibility of tooth breakout and destruction of • both the pinion and gear.

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COAL CRUSHING GEARBOXES CONVEYOR GEARBOXES

CMM INSPECTION SHAFT MOUNTED ALIGNMENT FREE GEARBOXES

DOUBLE OUTPUT EXTRUDER GEARBOX

SELF ALIGNING, TWIN PINION MILL DRIVE GEARBOX

GEARBOXRANGE

STANDARD RANGE

SPECIALS

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SELF ALIGNING DRIVES• Automatically maintains 100% gear

contact regardless of movement in foundations and/or driven component.

• Can use recirculating f iltered oil.• Reduced maintenance as alignment

checks and adjustments are eliminated.• Pow er to 10,000kW per gearbox.

GEARBOXES STANDARD• Completely designed and manufactured

in house using AGMA and DIN standards.

• Standardrange of multi stage drives.• Precision case carburised and ground

gearing to AGMA 14 for quiet reliable operation.

GEARBOXES SPECIALS• Special Gearboxes can be designed to

f it existing foundation as a direct replacement of your old drive. (Flender, Falk, Valmet etc.)

• Pow er upgrades, ratio changes and replacement parts available.

• Torque splitting gear drives.

INCHING DRIVESHofmann Engineering makes a range of inching drives to f it to new and existing mill and kiln drives. Features include:• Planetary main reduction.• Hydraulic or electric.• Integral or separate brakes.• Disengaging couplings.

BOGIE DRIVES• Complete motor, gearbox, coupling

assemblies for bogie w heel drives.• Spiral bevel gear input. These drives

are shaft mounted alignment free.

PLANETARY HIGH SPEEDPlanetary gearboxes for compact drive solutions. Case carburised gears, precision ground to ensure equal load sharing. Carbo-nitrided Internal ring gears. All gearing can be precision ground to DIN 3 (AGMA 15) to ensure quiet, smooth operation.

CONVEYOR DRIVE 3000KWConveyor drive gearboxes, shaft mounted or f loor mounted. Case carburised and ground gears. S.G. Iron Housings or Fabricated from Mild Steel.Supplied complete w ith cooling systems and condition monitoring if required.

CENTRIFUGE GEARBOX .Special purpose gearboxes designed and manufactured to meet the customer’s specification. This free f loating, inline drive replaces a complex and expensive planetary gearbox.

HIGH SPEED GEARBOXESHigh speed drives, speed increasing and speed decreasing, w ith white metal bearings w here appropriate. Gears ground to very high accuracy levels ( DIN 3). Units to 50,000 kW and 20,000 RPM input speed have been manufactured.

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GEARBOX REBUILD DIVISION

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ADVANCEMENT THROUGH TECHNOLOGY

using:

IMPROVED CASE HARDENED & GROUND GEARING

COMPUTERISED GEAR GEOMETRY & PROFILE OPTIMISATION

HIGH CAPACITY BEARINGS

IMPROVED SEALING & LUBRICATION

UPGRADE YOUR EXISTING GEAR DRIVES

MORE POWER & LONGER LIFE

QUIETER OPERATION

LEAK PROOF SEALING

RE-RATIO

NEW GEARBOXOLD GEARBOX

AUDITING YOUR GEARBOX REPAIR SHOP

Compare Others Hofmann

Do they have Gear Design and Consulting services? Are they members of any gear standard associations? (AGMA, DIN, ISO)

Do they have a certified Gear Inspection Laboratory to inspect gear accuracy?Can they provide computerized printouts of lead, involute and pitch?

Do they have a Co-ordinate Measuring Machine for checking bore alignment and size of gearbox housings?

Do they have gear manufacturing facilities for producing improved replacement gearing?

Do they have heat treatment facilities for replacement gearing, including qualified Metallurgists? Do they have carburizing, induction hardening, nitriding, quench & tempering and stress relieving facilities?

Do they have modern, climate controlled gear grinding facilities, capable of producing accurate gearing to DIN 3/AGMA 15?

Do they have a gearbox test bed facility for load test running gearboxes?

Do they have gearing trained site crews for installing and laser aligning gearboxes?

Do they have the equipment and know how to rebuild your gearboxes?

Hofmann Engineering has extensive experience rebuilding gearboxes, small and large, to exacting specifications. If you need your gearbox to run more efficiently Hofmann’s can help.

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SUGAR MILL GEAR INSTALLATION & ONSITE SERVICES.• Consultation and Inspection of complete drive • train including detailed analysis and reporting.• Laser alignment and installation of the complete • drive train.

HOFMANN ONSITE GEAR RECONDITIONING PROCEDUREUsing the Hofmann case hardened pinion as the accurate master and then precision in-situ grinding and using a special chemical etchant to in-situ recondition the w orn mating gear.

DRAGLINE & SHOVEL SITE WORKHofmann Engineering completely:• Inspect,audit and condition monitor critical • dragline and shovel components.• Do complete site installation including machining • and w elding.

ONSITE MACHINING SLEW BEARING• Design, manufacture and operation of • specialized on-site machining equipment to • solve your site machining problem.• Perform large site machining projects to 14m • dia.

ONSITE SERVICE

CONSULTATIONINSPECTIONMACHINING

FITTING

WORLD WIDE MILL AND KILN SITE INSTALLATION & SERVICEInstallation by the Hofmann Site crew of Hofmann Engineering manufactured girth gear, and a tw in pinion self-align gearbox, inching drive & electric motor at a Gold mine in Ghana.

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TRUNNION JOURNAL MACHINING AND REPAIR• Max dia: 3600mm.

• Remove/replace trunnion roller bearings

• using oil injection and specialized

• extraction and bearing installation jigs.

• Scrape in w hite-metal/bronze bearings.

RE-MACHINING TRUNNION FLANGE FACES• Max dia: 14000mm.• Onsite removal & installation of trunnion.• Onsite refurbishment & machining of mill • trunnions.

ONSITE MACHINING OF MILL SHELLS• Special trunnion journal alignment tooling • to insure that both trunnion journals are in-• line. • Mill refurbishment.• Shell crack inspection and w eld repairs • including stress relieving.

REPAIR TRUNNION BOLT AND LINER BOLT HOLES• Purpose manufactured tooling for • production drilling/boring and tapping.• Re-bore and sleeve w orn liner bolt holes • to prevent liner bolts f rom breaking.

OIL & GAS, RIG EQUIPMENT REPAIRSONSHORE & OFFSHORE• Onsite machining, f itting & laser • alignment.• Gearbox & gears manufactured and • repaired.• Pump and valves installed and serviced.

LASER ALIGNING• Laser alignments of drive trains for mills, • kilns, turbines etc. • Girth gear/pinion installation.• Gearbox bore laser alignment inspection• Engine block crankshaft bore alignment • inspection and rectification.

MACHINING GEARBOX MOUNTING FLANGE• Flange & bore refurbishment.• Site inspection and drafting.• Special purpose machinery designed and • manufacture to suit your application.• Bolt tensioning equipment.

LINE BORING ,WELDING AND ON-SITE MACHINING • Repair of bucket bores.• Onsite line boring – engine blocks, ship • propeller housings, crushers.• Line boring and drilling to 3m dia x 6m L.• Milling of keyw ays and surfaces.• Site Welding and heat-treatment.

KILN TYRE REFURBISHMENT BY IN-SITU GRINDING• Kiln roller and tyre refurbishment by • machining and grinding.• Crusher rolls in-situ grinding to remove • uneven w ear.

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KILNSERVICES

WORLD WIDE KILN SERVICES

• Consultation

• Inspections

• Alignment Surveys

• Refurbishments

• Tyre / Roller surface Reconditioning

• Gear installations

• Maintenance Planning

RECONDITIONING:

Rollers and tyres can be machined,ground or linished to recondition tyreand roller surfaces, correcting anyuneven wear and or taper using ourpurpose built reconditioning unit.

Our purpose built reconditioning unit canbe adapted to suit most rotary kilndesigns and can be transported worldwide to meet customer requirements.

Tyre & Roller diameters are measuredprior to and after reconditioning toconfirm profiles are flat and parallel tothe centre line axis.

MAINTENANCE PLANNING:

Major maintenance projects needcarful planning to ensure timelyand correct performance.

Correct procedures and methodsrequired in order to obtainequipment performance on startup.

Alignment tolerances maintainedduring installations and repairoutages.

ALIGNMENT:

Survey carried out using hard contactand fixed datum method.

Tyre & Roller diameters are measuredduring normal operation with the aid ofelectronic measuring device that isaccurate up to 0.10mm. This allowaccurate profiling for wear conditionsand averaging for alignment

Basis of the alignment is to achievecorrect alignment of the units actualcentre line which in turn is positionedin relation to the meshingcharacteristics of the main drive girthgear and pinion.

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1. KILN ALIGNMENT SURVEYINGSurvey by hard contact method.• Check alignment of the kiln.• Re-align kiln to ensure smooth running.

2. KILN CENTRELINE SETTINGThis enables datumns to be established from w hich future measurements can be taken.

3. ROLLER ALIGNMENTRollers are aligned using hard contact method from direct centre lines.

4. ROLLER & KILN TYER MEASUREMENTElectronic measuring of diameters accurate to 0.10mm.This is critical as part of the information needed to give correct kiln alignment.

5. MACHINING TYERS & ROLLERSMachining of roller by tool to obtain optimum material removal.Both kiln tyers and roller can be machined or ground on-site.

6. SHELL CHANGE-OUTShell change-out and straightening.• Shells can be site measured and then manufactured by us up to

15m in dia.• Site shell change out and straightening including in-situ sub arc

w elding can be performed by the Hofmann site team.

7. GIRTH GEARSGirth gear manufacture, installation, reversal, reconditioning and alignment.• Site measure pinions and gears.• Manufacture complete gearing in house.• Install and align w ith our site crew.• Site gear reconditioning available.• Hofmann open gear lubrication and lubricants also available.

SUGAR MILLS

PARTSAND

SERVICE

LOW SPEED PINIONS

• Through hardened (to 360 BHN).

• Induction hardened (to 55 HRC).

• Case-carburised (to 62 HRC).

• HofCarb carburised (to 62 HRC).

CAPACITY• Size: 1.6 m face x 2.0m dia.

• Quality: AGMA 12 (DIN 5).

LOW SPEED GEARING• SG Iron.• Cast Steel (to 320 BHN).• Austempered SG Iron (to 450 BHN).• Forged fabricated (to 360 BHN).• Forged fabricated induction

hardened (to 55 HRC).

CAPACITY• Size: 1.6 m face x 15 m dia.

• Quality: AGMA 10 (DIN 5).

RE-RIMMED GEARS• Remove old rim and weld new rim to

hub with full penetration welding.

Hofmann Engineering has the experience and technology to provide you with all of your sugar mill drive train needs. High & low speed gearing, shafts, lubrication and sealing solutions, crush roll pinions, planetary drives, consulting, onsite service and more.

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HIGH SPEED GEARBOXES• Replacement gearing and new gearboxes.• Ratio changes and pow er upgrades.• Case-carburised to 62 HRC and precision • ground to AGMA 12 (DIN 5).• White metal bearing manufacturing and • reconditioning.

CRUSH ROLL PINIONSCast to 300 BHN.Forged to 300 BHN and CNC cut to AGMA 6 quality. Eliminates casting inclusions that can cause fatigue fracture.Induction hardened to 55 HRC and CNC hard cut to AGMA 6 gives 200% improvement in pitting and 70% improvement in bending strength.

CRUSH ROLL PLANETARYPlanetary drives, use electric motors and eliminate crush roll pinions w hile still allow ing centre distance adjustmentPrecision gears, case hardened and ground to AGMA 12 quality.Standard modular design minimises spare parts capital and can be changed out in less than one shift.

GEARBOX SPECIALSSpecial Gearboxes can be designed to fit existing foundations as a direct replacement of your old drive. (Flender, Falk, Valmet, David Brow n etc.)• Pow er upgrades, ratio changes and • replacement parts available.• Torque-splitting gear drives.

LUBRICANT SUPPLYHofmann Lubrication division has an agreement w ith Klüber Lubrication of Germany AG to supply a range of products, directly formulated to Protect the Gearing that w e design and manufacture.

This forms an integral part of our Gear Protection Package.

LOW SPEED JOURNAL BEARINGS• White metal• Bronze• Pedestals and caps• High tensile studs and nuts• Full reconditioning and installation • available.

GEAR RE-RIMMING• Old gear material tested to ensure material • compatibility• Rim machined off leaving bare diaphragm.• New forged rim w elded to diaphragm by • submerged arc full penetration w elding.• Full contour induction hardening to 55 HRC • and hard cutting to AGMA 10• Full NDT to ensure integrity.

ONSITE INSPECTION & CONSULTING SERVICE• Inspection and assessment of your mill • and drive train.• Failure analysis including Engineering • and Gearing design review . Finite • Element Analysis and Metallurgical • Analysis.

ONSITE SERVICE• Laser alignment of gear trains.• Gear and pinion installation.• Reconditioning of w orn gearing using • Hofmann Engineering’s reconditioning • procedure.• White metal and bronze bearing • installation including scraping.

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OIL & GAS

PARTS AND

SERVICE

SUB-SEA BALL CHECK VALVESLarge 1500mm dia. Borsig Sub-sea Ball Check Valve completely overhauled and tested by Hofmann Engineering.

GAS LIQUIFYING PUMP MANUFACTURED AND TESTED UNDER LICENCE TO STORK.Hofmann Engineering continue to havelicensing agreements w ith recognisedOEM’s for the manufacturing, assembly,and shop testing of precision valves andpumps.

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With Western Australia's largest heavy engineering facility operating 24 hours per day, 7 days per weekHofmann Engineering is able to offer an unparalleled range of services to its clients. Emergencyrepairs and rapid rebuilds can be conducted on a w ide range of machines, components and specialtools, complete w ith compliance documentation to most international codes and standards.

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SUBMERGED ARC WELDING OF SUB-SEA BALL VALVEThe ball v alve is submerge arc welded and heat treated in an electric furnace (stress reliev ed). Welding performed to detailed w eld procedure.

BALL VALVE FULLY MACHINEDBall precis ion machined to giv e 100% clean up. Full magnetic particle and ultrasonic crack detection.

BALL VALVE FINISH GROUNDThe ball is Hard Chromed and then finish ground to a 0.02mm roundness tolerance and polished to a 0.4 micron surface finish.

BALL VALVE ASSEMBLYAssembly is handled by our specialist valve technic ians. Where required the assembly is carried out in a purpose built clean room.

BALL VALVE PRESSURE TESTINGDue to safety requirements many high pressure v alves are pressure tested in a below ground concrete w alled pit. Certification for the testing is prov ided.

SWAGING TOOL REBUILT AND MODIFIEDPile Reforming Tool for Goodwyn A Platform for straightening bent py lons. This tool w as re-engineered, part manufactured and then tested by Hofmann Engineering.

TOP DRIVE DRILLING SYSTEMSWe supply replacement parts including all gears as w ell as rebuild services.Gearing case hardened and ground to DIN 5 quality .

WINDLASSWe supply replacement parts including all gears as w ell as rebuild services.This includes both the capstan, brakes and gearbox driv e system.

TRIPLEX SLUSH PUMPSReplacement parts for common makes like National including gears, crankshafts, etc. Rebuild and repair serv ice.

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• Standard Helical.• Planetary.

All makes overhauled and rebuilt after marketwith improved high performance casehardened precision ground gearing. Thisensures smooth, quiet, reliable operation.

• Flender.• Renk.• Valmet.• Hansen.• L&S• Metso• Clipper.• Gamesa.• Eickhoff.• Zollern.

WIND TURBINE

GEARBOXES

Slew Bearings - Induction hardened and precision ground..

WIND TURBINE GEARBOXES - New and Rebuilt.

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ONSITE MACHINING & MEASURINGPrecision portable co-ordinate measuring machine for checking bore alignment and accuracy insitu.Portable line boring for remachining worn gearbox housing insitu.

HofmannCompare

SITE INSTALLATION AND SERVICEDo they have gearing trained site crews for installing and laser aligning gearboxes? Are they able to provide on-site machining services?

GEARBOX BACK TO BACK LOAD TESTINGDo they have a gearbox test bed facility for load test running gearboxes? Hofmann Engineering has full load gearbox test running to 2000kW.

GEAR GRINDING – PRECISION – EXTERNAL & INTERNALDo they have modern, climate controlled gear grinding facilities, capable of producing accurate gearing to DIN 3/AGMA 14 required to produce quiet running wind turbine gearing?

HEAT TREATMENTDo they have heat treatment facilities for replacement gearing, including qualified Metallurgists? Carburizing, induction hardening, nitriding, quench & tempering and stress relieving facilities? Gas carburising to 1800mm dia for the output stage gearing for wind turbines.

MACHINING / FABRICATIONDo they have gear manufacturing facilities for producing improved replacement gearing? Hofmann Engineering also fabricate and machine many of the wind turbine components.

CO-ORDINATE MEASURING MACHINEDo they have a Co-ordinate Measuring Machine for checking bore alignment and size of gearbox housings? This is required for the planet carrier of the planetary stage on wind turbine gearboxes and components.

GEAR INSPECTIONDo they have a certified Gear Inspection Laboratory to inspect gear accuracy? Wind turbine gearing requires very high gear accuracies of DIN 3 or better.Can they provide computerized printouts of lead, involute and pitch?

GEAR DESIGNDo they have Gear Design and Consulting services and a full metallurgical laboratory for carrying out failure analysis? Are they members of any gear standard associations? (AGMA, DIN, ISO)

AUDITING YOUR WIND TURBINE GEARBOX REPAIR SHOPDo they have the equipment and know how to rebuild your gearboxes?

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COMPLETE TURBINE WORKSHOP OVERHAUL• 200 Ton Crane Facilities

• Bead Blasting Facilities

• Metrology Laboratories

• Turning to 4m dia x 35m long

• 6 x Floor borers up to 18m travel

• 9 x Vertical Borers (4 CNC)

• 5 x Co-ordinate Measuring Machines

• 2 x Portable Measuring Machines

• 2 x Laser Tracker

• Largest Heat Treatment Facility in Australia

• 7 x 5 axis machines including hard machining of titanium

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ENERGY POWER

STATIONS

Steam Turbines

Coal Pulverising

Gas Turbine Gearboxes




MANUFACTURE• New seals from castings (including S/S)

or forgings. Re-engineering from samples.

REFURBISHING• Re-caulking of seal strips to refurbish

diaphragm seals.

MACHINING• Machining a casing on a floor borer.

Check split face for distortion and remachine if necessary.

MACHINING• Rotor of approx Ø3m. Removal of

blades and finish machining of new blades.

INTERNALS OF A GAS TURBINE GEARBOXAbility to fully inspect, manufacture and refurbish all components.• Precision Grinding of the gearing to Din

3 quality.

REFURBISHINGGas turbine gearbox that is being stripped, assessed, completely refurbished and load tested.

COAL MILL GEARBOX REFURBISHMENTS• Onsite removal• Manufacture of components• Worm & w heelmanufacture• Total refurbishment• Onsite installation

ONSITE SERVICESOnsite measuring using our portable coordinate measuring machine. This can measure in a single set up Ø2.4m to an accuracy of 0.025mm (0.001”). Photo show s performing f latness check on a low er casing. Compliments our Laser Tracker w hich can span 25m in one setup.

SPARE PARTS

• Studs from High Temp Steel

• S/S Springs

• Governor valves, rollers, positioner etc

• Cylinder locking strips

• Control shaf ts

OVERHAULING A COMPLETE TURBINE ARRANGEMENT

• Total overhaul w ithin the one premises

• Customer off ice available on request.

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UDD MECHANICAL CONVERSIONSHofmann Engineering Pty Ltd completely designed, manufactured and installed the mechanical drive for the UDD (Universal Dig & Dump) dragline.

Our concept provided a free-floating, alignment-free, shaft-mounted, modular gearbox that bolts to the side of the rope drum. This gearbox contains HofCarb carburized and precis ion ground gearing with a filtered oil recirculation system.

Being shaft-mounted and modular enables this gearbox to be pre-test run and changed out in under one shift without requiring any re-alignment.

INPUT MOTOR PINIONS• Double Helical Hard Cut Narrow

Gap. Case Carburised to 60-62HRC & finished to AGMA 12 quality.

• Single helical case hardened. These are fitted with eccentric cartridges and spherical roller bearings. This assembly fits straight into the Bucyrus hois t or drag gear case bore. The eccentric cartridges enable simple mesh adjustment without having to re-bore the gear case.

• Quench & tempered to 360 BHN and cut to AGMA 10 quality as per OEM design.

• Carb Bearing Alignment Technology with Eccentric Cartridges can also be used on Bucyrus machines to give over a 200% improvement in bearing life.

SWING RACK ASSEMBLIES• Alloy Steel Forged Rack Rims Q&T to

330BHN Combined with fabricated construction.

• High performance racks with a unique heat treatment procedure that increases the hardness to 450BHN.

• Swing Pinions are full contour induction hardened.

OEM Design

Hofmann increased face w idth narrow gap

DRAGLINE

REPLACEMENT PARTS

BUCYRUSMARION

P&HPAGE

UDD MECHANICAL CONVERSIONS

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DRUM GEARS• New Forge Fabricated Gears 330 to

360BHN precision cut to AGMA 10.• M echanically Re-RimmedGears

Replace only the gear teeth to save time and money.

• Re-Rimmed GearsRemove old rim and w eld new rim to hub w ith submerged arc full penetration w eld.

INTERMEDIATE ASSEMBLY• Intermediate Gear Forge fabricated,

staggered tooth, double helical, through hardened 330 to 360BHN, precision cut to AGMA 10 quality.

• Intermediate ShaftForged, spline coupling carburized to 60-62HRc, Precision cut to AGMA 12 quality.

• CARB Bearingsincrease bearing life by up to 200%.

SELF ALIGNING PINONS• Self-aligning Gearing technology

maintains 100% contact in operation.• Double helical zero-gap 19” face width,

carburized to 60-62HRc and precision ground to AGMA 12 quality.

• Spherical Bearingscarburized to 60-62HRc and lapped for 100% contact, oil lubricated.

PROPEL GEARS• New or Reclaimed hub. • Reversible gear rim on the same side

hub thus doubling the life of the gear.• Mechanically Fastened Rim can be

replaced independently of hub.• Gear Rim Forge fabricated, through

hardened gear 330 to 360BHN, precision cut to AGMA 10.

PROPEL SHAFTS• New Shafts of high quality alloy forging

w ith a higher forging reduction.• Quench & Tempered to achieve

hardness of 320-360 BHN.• Pol ished & Shot Peened Radii &

Transitional areas to increase strength.

PROPEL ECCENTRIC• Eccentr ic casting fully machined in-

house• Forged fabricated version from

AS1444-4330 steel• Full refurbishment by welding and re-

cutting of splines

ROPE SHEAVES• New forged fabricated full contour

induction hardened to 55HRC for a case depth of 6mm.

• Repaired sheavesby full penetration submerge arc w elding the w orn groove and then induction hardening.

8200 HOIST ARRANGEMENT• M odular Design allows quick and easy

change out.• Rigid constructionreduces distortion

and gear misalignment.• Interchangeability between gearboxes

and gearing.• Self-aligning technology maintains

100% contact during floor deflection.

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SHAFT MOUNTED GEARBOX• M odular Design allows quick and easy

change out in one shift.• Rigid Construction reduces distortion

and gear misalignment.• Free Floating isolated from dragline floor

distortion.• Alignment Free gearbox bolts directly to

the hoist drum.

ROPE DRUM DESIGN• Fini te Element Analysishas been

conducted in order to eliminate the inherent OEM rope drum internal stiffener cracking problem

• Hofmann Engineering Pty Ltd designremoves all internal lateral stiffeners and increases the drum shell forging thickness to reduce stress.

ROPE DRUM MATERIAL• Hofalloy2 Forged Plate has been

specifically formulated by Hofmann Engineering Pty Ltd to accommodate industry requirements. The result is a Quench & Tempered high alloy steel suitable for induction hardening, machining and fabricating. Stocked quantities are maintained in order to reduce lead-times

ROPE DRUM ROLLING• The stocked Hofalloy forged plate rolled

into a perfect cylinder using Hofmann Engineering Pty Ltd.'s, 5000 ton Vertical Rol l Press.

• The above drum is 150mm thick 1900mm long and w ith an OD of 2947mm, in its rolling condition it is approx. 300 BHN.

ROPE DRUM MACHINING• All Rope Drums are fully machined in-

house from the initial fabrication preparations right through to cutting of the rope grooves, turning of the flanges and drill and tapping of the holes. This ensures that complete control of the project is maintained and the highest standards of quality are guaranteed.

GEARBOX MODULE• M aintenance and testing of gearbox can

be done in a clean w orkshop rather than inside the dragline.

• Installation requires less skill and accuracy with the self aligning pinion.

• Gearing forged, HofCarb carburised to 60-62HRc, precision ground to AGMA 12

INDUCTION HARDENING • New Forge Steel drums fully fabricated

using full penetration w elds and then full contour induction hardened to 55 HRC for a case depth of 6mm.

• Worn Drums. All cracks removed before building up w ith 30mm of submerged arc w elds and then induction hardening

ROPE DRUM CLAMPS• Unique design developed by Hofmann

Engineering Pty Ltd.• Clamp is integrated into the rope drum

center f lange.• Precision machined.• Case Hardened. • Optimized for w eight. • Greater clamping force.

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1 2

3 4

OEM Drum Hofmann Drum

5 6

PROPEL CAMSHAFT/ASSLY• New quality high alloy forgings either

in 4340 or EN26 Quench & Temperedw ith transition areas polished & shot peened.

• The propel cam can be w eld repaired to improved hardness or manufactured as a new casting.

SWING SHAFTS• New shaftsof high alloy forged steel• Repair Worn out splines and bearing

Journals to as-new condition using a technically advanced, individual w eld & Heat Treatment procedure.

SWING PLANETERY

• The swing gears are manufactured from high quality alloy forgings and heat treatment to increase load carrying capacities.

• All the gearings are ground to higher AGMA quality

RACK SEGMENTS.

• Swing Racks Forged fabricated design w ith High Alloy steel forged segment.

• Induction Hardened full contour induction hardened to 45-49HRc 8mm thick case.

• Impact Resistant Core hardness of 280-310BHN.

SWING RAILS & ROLLERS• Upper and Lower Rails High Alloy steel

forging Q&T to 340-360BHN and precision CNC machined.

• 3rd Rail Design.• Rol lersHigh Alloy steel forging Q&T to

410-415BHN and precision CNC machined & Flangeless Roller design

• The rails & rollers are trial assembled using our laser tracker.

. SWING PINIONS• Forged High Alloy steel precision

ground to AGMA12.• Induction Hardened full contour

induction hardened to 54-58HRc 8mm thick case.

• Impact Resistant Core hardness of 280-310BHN.

CENTRE PINTLE• Designed using FEA modeling to

reduce magnitude of stress and reduce stress concentrations.

• New forged steel construction to overcome cast steel cracking problems.

• Forged steel Centre Pintle used on P&H 9020 in operation since 2002.

SWING BASE (TUB)

• Full onsite measure, in-house 3D modelling and design of the complete Tub, Racks, Rails, Rollers & Centre Pintle

SWING BASE (TUB)

• The five individual modules are fully assembled in our w orkshop for your inspection prior to transporting to site & erection into your one piece Base

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HOIST GEARBOX PINIONS• Forged alloy steel• Case Carburised Pinion, 58-62HRc,

precision ground to AGMA 12.• As per above examples of P&H 4100A

Hoist Input Pinion, and Bucyrus495 Hoist Intermediate Pinion.

SWING PINIONS• Pinion Shaft Quenched & Tempered• Induction HardenedGear teeth & Spline

before f inally shot peening the stressed shaft area. The F.E.A. performed on this re-design confirms a 50 x life improvement.

• Pinion can also be supplied fully assembled w ith Bearing & Cartridge ready to install.

HOIST ROPE DRUMS• New Forge Fabricated alloy steel rope drum,

Induction hardened 56-58HRc.• Induction hardeneddrum seal.• New Forged Alloy Steel Drum Shafts

through hardened.• Service Exchange and re-lagging available.

HOIST DRUM GEARS• New Forge Fabricated Drum Gear 330-

360BHN core hardness.• One piece T-section construction.• Full Contour Induction hardenedgear teeth

to 54-58HRc and precision ground to AGMA 10 quality.

SHOVEL

REPLACEMENT PARTS

BUCYRUSMARION

P&HPAGE

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SPLIT SWING GEAR ADVANTAGES: • Shovel only need be separated not de-decked• Replaceable thrust rail• Universal bolt pattern• Stronger, harder teeth

FULL CONTOUR INDUCTION HARDENINGalong full involute without tempering back the tooth tip.

The effective case depth is varied from 8mm at the tooth tip to 10mm to eliminate a hard brittle tooth tip.

SWING SHAFT ASSEMBLIESImprove the life of your Swing Shafts with Hofmann

Engineering Pty Ltd positive stop shoulder design that prevents the sleeve moving during thermal expansion thus

eliminating loss in bearing preload.

10mm

8mm

Positive stop

Sleeve design Shaft design

Fitted bolting sleeve also helps retain the split joint.

2 Fitted Dowel Bolts with Hofnuts secure the split line with 190T of clamping force.

HOFMANN BOLTED SPLIT LINE DESIGNthe solution to split line tooth cracking

Positive shoulder on shaft prevents the bearing sleeve moving during operation

thus bearing preload is maintained

Tapered joint face and Hofnuts prevent tangential separation force and hence fatigue cracking

Replaceable Thrust Rail

SHOVEL SWING GEARS

& PINION SHAFT

ASSEMBLIES

P&HMARION

BUCYRUS

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1. Second reduction sun pinion eccentric thrust kit to reduce wear and prevent damage to pinion.

2. Induction hardened 43Tooth propel shaft to 54-56HRc to give substantial fatigue cracking resistance.

3. 43Tooth output spline is upgraded to 47Tooth spline for higher load carrying capacity.

SHOVEL PLANETARYGEARBOXES

P&H 2800XPAP&H 2800XPB

P&H 4100AP&H 4100XPBBUCYRUS 495B

BUCYRUS 495HR

PROPEL&

SWING

HOFMANN UPGRADED PLANETARY TRANSMISSIONSNew or Service Exchange. Gain more life from your transmissions

SERVICE EXHANGE PROGRAM:

1. Full strip and assessment.

2. Replacement of bearings and seals.

3. NDT inspection of all components.

4. “Failed Steel” repair/replacement.

5. Reassembly and test run.

6. Comprehensive service reports.

1. Higher quality materials and heat treatment to increase load carrying capacity.

2. SKF bearings for superior quality and life.

3. Form ground gearing to AGMA 12 minimum quality.

4. Higher quality materials and SKF bearings for output pinions.

BUCYRUS:HOIST, SWING AND PROPEL TRANSMISSIONS NEW, REFURBISHED AND UPGRADED:

INDUCTION HARDENED REGION

4. Second and third stage ring gears are through hardened and accurately cut to AGMA 10 quality

5. 43Tooth output spline is upgraded to 47Tooth spline for higher load carrying capacity.

P&H: SWING AND PROPEL TRANSMISSION UPGRADES:

495HR Swing Transmission 495HR Hoist Transmission 495HR Propel Transmission

3rd Reduction Ring Gear

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HOIST & CROWD GEAR BOXES• Hoist, Sw ing, Crow d and Propel.• Overhauled & New .• Like For Like Replacement Internal • Gearing or Upgraded to match todays’ • technology of Case hardening by • Carburising or induction hardening.• Full AGMA Quality Inspection carried • out on all Gearing.

DIPPER RACKING• Cast Manganese Steel through

hardened.• Cast Alloy Steel through hardened .• Forged alloy steel with machined tooth

prof ile through hardened 320-360BHN. Guarantee pitch and accuracy.

CROWD PINIONS & RACKS.• Forged steel machined, heat treated • Precision machining of teeth.• Full range for all makes and models.• Dipper RacksCast Alloy or Manganese

Steel as per OEM. Hofmann Improved Forged Alloy Steel w ith machined tooth prof ile.

ROPE SHEAVES.• New Forge fabricated design.• Rebuilt by submerged arc w elding.• Re-prof iling to original dimensions.• Full Contour Induction Hardening to 54-

56HRc.

BOOM REBUILDS.• Striped, Assessed & Evaluated.• Repaired to remove all cracking.• Fully stress relieved.• Finish machined in single setup.

DIPPER AND DIPPER ARM• Full or partial Rebuilds.• NDT Inspection & Repairs.• Onsite line Boring & Welding w ith the Hofmann Line Boring Machine.

• Pins, Bushes & Link replacements.• Latch bars & Latch Levers. Full range for all makes and models.

PINS AND BUSHES• PINS deep case Induction Hardened

and • precision ground.• Bushes Designed and manufacture to • suit your f ield requirements.• Selections of Materials, Heat Treatment, • Lubrication groove design & Coatings.

SPLINE & SHIPPER SHAFTSREPLACEMENT GEARS• Replaced With New Or Weld Repaired.

Replacement gears and components for all areas of your shovel.

TRACK PADS• M anganese Steel Up To 18%• Alloy Steel quench and tempered• Induction Hardened Alloy Steel

quench & tempered and then deep case Induction Hardened on running path and in the track connecting bores.

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HYDRAULICEXCAVATOR

REPLACEMENT PARTS

BUCYRUS TERREX - O & K

KOMATSU LIEBHERR

CATERPILLAR

When it comes to designing machines that can be all things to all people OEM’s are always between a rock and a hard place. In the final product, this inevitably leads to compromises.

We have the flexibility and expertise to custom design

components that will provide outstanding performance

in your particular application

SLEW RINGS AND BEARINGS

Track Pads

Replacement parts

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PINS• Deep case Induction Hardened and precision ground.• Retro-f it “f loating” pin designs available.• We can offer a range of solutions to individual pin problems,

including re-design of lubrication paths either through pin or bush to achieve considerable life expectancy gains.

BUSHESDesigned and manufactured to suit your specific requirements.A selection of:• Materials.• Heat Treatment processes.• Surface coatings.• Lubrication groove design. Traditional f igure eight or fish-

netting is available.

TRACK PADS• Manganese Steel Up To 18%.• Alloy Steel quench and tempered.• Induction Hardened Alloy Steel quench & tempered and then

deep case Induction Hardened on running path and in the track connecting bores.

PLANETARY GEAR BOXES

(Slew and Final Drive)• Full or partial strip dow n.• Replaced w ith new improved high performance gearing.• Fully assembled, test run & technical report submitted.• Onsite inspections also available.

SLEW RINGS AND BEARINGS• Manufactured new , or refurbish your old components.• Re-machine, induction harden and fit oversize rollers to reclaim

w orn slew bearings.

PRODUCT IMPROVEMENTSON REVERSE ENGINEERED PARTS.• Co-ordinate Measuring Machine to ensure precision

measurement of components. • Metallurgical Laboratory to analyse Chemistry, Hardness &

Microstructure.• Engineering Office with full CAD, CAM, FEA and gear design

software.

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RECLAIMER/STACKER/CRANE SLEW BEARINGS• KRUPP

• VOEST ALPINE

• O&K

• MITSUBISHI

• FAVCO

HYDRAULIC EXCAVATOR SLEW BEARINGS• CAT

• KOMATSU

• LIEBHERR

• O&K

• DEMAG

DRAGLINE/SHOVEL

SLEW BEARINGS• BUCYRUS

• MARION

• P&H

• PAGE

SLEW BEARINGS

NEWREPAIRED

ALL MODELS TO 16M DIA

SLEW BEARINGS AND SLEW GEARS

Designed to meet your requirements, manufactured from your draw ings or reproduced from your samples. The Hofmann Engineering Team w ill design your Slew Bearings using the latest design software and Computer Aided Draf ting to DIN, AGMA, British or Australian Standards.

Hofmann Engineering is unique. We have a complete design manufacturing and testing facility for Slew Bearings in house. This ensures the fastest possible delivery time and guarantees the quality of our f inal product. Each stage of manufacture is monitored through our Accredited ISO 9001 Quality Assurance system available for split conf iguration or full circle.

Induction Hardening of bearing surfaces of the Slew Bearing, and/or the gear teeth, is carried out using the latest technology. We have more than 20 years experience in Surface Hardening techniques.

Each Slew Bearing is supplied w ith full certification covering Material, Heat Treatment and Dimensional Checks. Hofmann Engineering’s experience in this f ield extends to over 100 complete slew bearings of various types.

On Site Inspection, Consultancy, Machining and Installation are also available.

Both New and Repaired Replacement Slew Bearings and Slew Gears To Suit the Following:

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DESIGN & DRAWINGOur team of highly trained Engineers will prepare plans from your existing Slew Bearings or new designs can be made to fit your requirements.

VERTICAL BORINGA range of Vertical Boring machines for turning of Slew Bearing Rings up to 16 metres in diameter.

GEAR CUTTINGExternal and Internal Gear Cutting on our extensive range of CNC and Conventional gear cutting machines.

INDUCTION HARDENINGIn addition to induction hardened bearing raceways we also offer tooth by tooth full

contour induction hardened gear teeth. This process produces a hard w ear resistant case up to 10mm deep, supported by a tough impact resistant core.

INSPECTION LABORATORYCo-ordinate measuring machine w ith lead involute and pitch sof tware to enable the complete inspection of components in a climate controlled laboratory environment.

ASSEMBLYAll slew bearings are trial assembled prior to despatch.

FROM OLD...

Our experience with Slew Bearings is second to none, and we are able to deliver the finished article on time, to precise parameters.

... TO NEW

Com puterised full contour induction hardening of large Slew

Gears and Bearing Race Ways

Ha rd Wear Resistant Case:Max Case hardness = 58 HRCMax Case depth = 10 mmMax residual compressive stress depth = 10mm

Sectioned test piece showing the induction hardened profile

Tough Impact Re sistant Core:Core hardness

= 300BHN

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Hofmann Induction Hardened Alloy Steel Trackpads provides the ultimate in wear resistance and toughness that modern technology can at present offer. This is why tracked earth moving equipment that requires long travel life uses this technology almost exclusively. Hofmann Engineering also offers Alloy Steel and Manganese trackpads that are interchangeable with the OEM. For customers looking for that extra performance, these can be upgraded to induction hardened alloy steel trackpads.

HOFMANNTRACKPADS

Designed to Excel …

Engineered to Outlast

1) INDUCTION HARDENED ALLOY STEEL

Highest Wear Resistance and Strength

• HITACHI (manufactured exclusively for Hitachi)• LIEBHERR• O&K (TEREX) • KOMATSU

Hofmann Engineering’s Hydraulic Excavator Trackpads are made from High Alloy Cast Steel and are Induction Hardened to provide the ultimate in life and performance for the large amount of traveling these machines need to do.

2) ALLOY STEELGood Strength and Stretch Resistance

• BUCYRUS• MARION

Alloy steel trackpads are used as they do not require deformation to increase hardness, The alloy properties have been chosen to ensure minimal deformation in w orking areas of the trackpad. To improve w ear resistance and strength these pads can be induction hardened.

3) MANGANESE Cost Effective

• P&H

Manganese trackpads are now only used by P&H. They provide a cost effective material that gives good toughness and w ork hardening properties. Hofmann Engineering also offers interchangeable P&H pads in induction hardened alloy steel for those customers looking for longer life.

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INDUCTION HARDENED ALLOY STEEL

ALLOY STEEL

MANGANESE

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11. FINAL INSPECTIONTrackpad castings are fully dimensionally Inspected including UV crack detection to ensure highest quality standards are met.

5. CASTING INSPECTIONThorough inspection of the castings is undertaken so as to ensure no less than a top quality product for our customers.

10. TEMPERINGTrackpads are tempered after Induction Hardening to improve impact strength and durability in induction hardened zone.

4. QUENCH AND TEMPERINGAlloy steel trackpads are quench and tempered w hich results in an excellent combination of mechanical properties.

9. INDUCTION HARDENING BORES Combined w ith hardened pins, w ear resistance is greatly increased, resulting in an overall low er w ear rate.

3. CASTINGWe have a number of foundries w orld-wide that w ork to our precise specifications in supplying our pad castings. Hofmann personnel manage, audit and inspect each step of the casting process.

8. INDUCTION HARDENING DRIVE LUGSDistortion due to w ear is reduced, resulting in longer effective lifespan of the drive lugs and the drive tumbler, and hence effectively the entire undercarriage.

2. SPECIFICATION DEVELOPMENTDetailed specifications are prepared to cover the complete manufacturing process from start to finish. A Portable Coordinate Measuring Arm is used to aid precise product development and inspection.

12. PACKING & DESPATCHTrackpads are painted and palletized for transport and despatched according to the customers order.

6. CNC MACHININGTrackpad Bores are Precision f inish machined on our state of the art range of Dörries Scharmann CNC Machining Centres.

7. INDUCTION HARDEN-ING RUNNING PATH A detailed explanation of Induction Hardening is show n on the next page. Note that manganese trackpads can not be induction hardened due to their material properties.

1. DESIGN & DRAWINGOur team of highly trained Engineers w ill prepare plans from your existing Trackpads or new designs can be made to fit your requirements. 3-D modeling using Solidw orks and Finite Element Analysis (FEA) are used to optimise design performance. 1

2

3

4

5

7

8

9

10

11

COMPLETE MANUFACTURING PROCESS CONTROL GUARANTEES QUALITY AND PERFORMANCE

6 12

Bore hardened to 8.5 mmDriving lug case depth 13 mm

Note: Case ContourRunning surface case depth 17.5 mm

The main advantage of induction hardened trackpads, pins, rollers and drive tumblers is improved wear resistance and increased resistance to plastic deformation. In addition to that, by Induction Hardening, we are generating compressive stresses in the surface of the part and that increases fatigue resistance. By selecting the right material and hardness for individual components, wear can be controlled even further.

A hardened case depth of 15mm or more is selected as these parts can be subjected to excessive wear before replacement and this assists in preventing case crushing.

We offer induction hardening of drive lugs, roller surfaces and Pin bores. Alternatively bores can be fitted with case hardened bushes (carburised to 3mm). Pins are normally made of either 4140 or 4340 and are quenched, tempered and induction hardened to required depth. Case Carburised Pins are available for extreme working conditions where the pins have proved to be wearing excessively.

Trackpads that are to be induction hardened are made from a high alloyed steel that is first normalised and tempered. The trackpads are then quench and tempered which results in an excellent combination of mechanical properties.

INDUCTION HARDENING OF TRACKPADS

Deep Engagement style

Offset Roller path for smooth operation.

Komatsu• PC3000• PC5500• PC8000

Induction Hardened Alloy Steel. Induction Hardened bores, Roller path and Drive Lug.

Hitachi• EX 2500 • EX 3600• EX 5500Modif ied Heavy pads can be made for extreme w orking conditions & applications.


O & K• RH120C • RH120E• RH170E• RH200• RH340


Liebherr

• 994

• 995

• R996 Single Pin

• R996 Twin Pin


P&H• 2300

• 2800

• 4100A

• 4100XPB DELTA®

• 4100XPC

Cast Manganese, Work Hardening

For extra life these can be offered in the Hofmann Deep Engaging style which are interchangeable with the P&H DELTA® pads.

For ultimate performance these can be supplied in Induction hardened Alloy Steel.

Bucyrus/Marion

• BE 495 Shovel

• BE Drills

• Marion 301

Alloy Steel quench and tempered with manganese welded in bushes .

These can also be offered with Induction Hardened bores, Roller path and Drive Lug.

HOFMANN TRACKPADS

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MINING TRUCK PARTS

MECHANICAL &

ELECTRIC FINAL DRIVE

TRANSMISSIONS

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Cracks

Designed to meet your requirements, Hofmann Engineering Pty Ltd Mining trucktransmissions are manufactured from your drawings or reproduced from yoursamples. Hofmann Engineering Pty Ltd has complete design, manufacturing,assembly and testing facilities to produce your mining truck parts. The processinvolves strip and assessment, product improve, assembly and testing of allcomponents and meets all internationally recognised gearing standards and qualityassurance standards. Hofmann Engineering Pty Ltd also provides site inspection,consultancy, machining and installation services.

PRODUCT RANGEOur product range incorporates both Mechanical and Electric final drivetransmissions and associated components for the following mining trucks:

CATERPILLAR: 797, 793, 789, 785, 777, 772, 771 series.

KOMATSU: 930E, 830E, 730E & 630E series.

GE WHEEL MOTORS: 772, 776, 787 & 788 series.

HITACHI: Via OEM only.

LIEBHERR: T282, T262 & T252 series.

SPINDLE RE-MANUFACTURING PROBLEMS• Finite Element Analysis of the spindle

showing the structural integrity.• Stress analysis through tensional loading

and vertical loading.• Cracking at the bearing area and spline

was due to high stress.

REFURBISHMENT SOLUTION• Crack detection and defect assessment.• Metallurgical and heat treatment analysis

of the parent material.• Machine away cracked area and

submerge arc build up and remachine to as new condition.

• Heat treatment and controlled induction hardening of spline area 52-56HRc to prevent fatigue cracking.

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GE MOTORIZED WHEEL KOMATSU TRUCK• Complete strip and assessment.• Worn gearing can be re-ground on our

precision gear grinders.• Badly w orn and pitted gears w ill be

replaced w ith new improved high performance gears meeting DIN,AGMA and Australian Standards.

• Full assembly and test run.

RING GEARS• Induction hardened full contour tooth by

tooth to 52-56RC and then precision ground to AGMA 12 minimum quality.

• New or w eld repaired as per customer requirement.

RING GEAR INDUCTION HARDENED• Computerized Induction hardening

facilities. • Full contour tooth by tooth induction

hardening of ring gear ensures both root and flank is hardened.

• Capable of achieving a case hardness up to a depth of 10mm and tough impact resistant core hardness.

CNC FORM GRINDER FOR HIGH PRECISION GROUND GEARINGHofmann Engineering has a high precision Hofler rapid 2000 form grinder w hich can grind both internal & external gearing, w orms and form cutters. This new machine has set a new benchmark of AGMA 13 or up as high as an impressive AGMA 14 for these gears.

PLANET GEARS AND PINION SHAFTS• Precision ground and timed gear set

assemblies.• Multiple assemblies matched for gearbox

installation (Load Sharing).• DIN Or AGMA QA inspection.

PRODUCT IMPROVEMENTCATERPILLAR PLANET GEARSHeat treatment Case carburising in action.• Chromium carbide precipitation reduces

coef f icient of friction between working components, increases residual compression and w ear resistance.

• Increase in fatigue resistance in the roots of gears.

• Shot peened root.

GEAR GRINDING• Fully CNC controlled gear grinding

facilities capable of achieving DIN 3 specification.

• Complete climate controlled area.• Prof ile and lead modif ication facilities.

GEAR INSPECTION• On Klingelnberg PSFU for authentication

of lead, involute & pitch.• Gear inspection to International

standards.• Ultraviolet crack detection.

FINAL DESPATCH• Finish gear coated w ith Molybdenum

disulphide C220.• Corrosion protected.• Fully protected in fumigated timber crate

for air freight & sea freight.

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EXCAVATORS &

RECLAIMERS

REPLACEMENT PARTS

KRUPPO&K

VOEST ALPINEMITSUBISHI

OLD BUCKET WHEEL GEARBOX

NEW BUCKET WHEEL GEARBOX

The Bucket Wheel and fully enclosedBucket Wheel Gear box situated atthe end of the boom.

Hofmann Manufactured new BucketWheel Gear box (630kW) completewith torque arm (see over forfurther details).

An operational Bucket Wheel Reclaimer transferring coal onto an overland conveyor.

RECONDITIONED

AN ALTERNATIVE TO NEW IS RECONDITIONED

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BOGIE ASSEMBLIESComplete bogie assemblies including fabrication, machining and assembly of equalisers plus supply and assembly of gearbox / motor and wheels .

SLEW BEARING to 15M

Designed and manufactured to suit your specific requirements, or re-engineered from sample.Induction hardening of the bearing surfaces is carried out us ing the latest technology.Each Slew Bearing is supplied with full certification covering Material, Heat Treatment and Dimensional Checks.

ONSITE MACHINING OF SLEW BEARING• Perform large site machining projects

up to 14m dia.• Slew bearing installation and

alignment also performed by our skilled technicians.

ROLLING THE SLEW GEAR RIM FORGED HOFALLOY PLATE10.2 metre forge/fabricated slew gear manufactured from AGMA grade 2 plate during the initial rolling of the rim plate. The plate shown is 150mm thick, however plate is stocked up to 220mm thick.

GEAR CUTTING THE SLEW GEARThe 4 segment 10.2m dia slew gear is being cut as an assembled ring. This ensures accurate pitching over all the split lines.• Individual segment lengths from 1m

to 12m possible.

FINAL PREPARATION OF COMPLETED SLEW GEARFinal preparation for despatch including corrosion protection prior to securing in fully enclosed crates.• Assembly simplified by having long

segment lengths.

TORQUE SPLITTINGBUCKET WHEEL GEARBOXOne of the most complex gearboxes to be manufactured at Hofmann Engineering. The gearbox is fully fabricated in 3 sections from grade 350 plate and weighs 22 tonnes when complete with torque arm.

BUCKET WHEEL GEARBOXThe gearbox comprises all carburisedand ground gearing from the spiral bevel input stage to the torque splitting arrangement achieved through the planetary stage, “the circular cas ing on the outside of the gearbox encloses the planetary stage gearing”.

SITE SERVICE• Complete assembly of stackers and

reclaimers.• Site inspection including

• slew bearing and gear measurements

• crack detection both MPI and UT• gearbox inspections

• site fitting including gearbox, slew bearing and bucket wheel change outs

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RAIL

Wheels & AxlesTraction Gearing

BogiesComponents

• GE• Alco• Siemens• Voith• Hitachi

Hofmann Engineering has provided engineered rail solutions for over 40 years andis a single source provider for all types of machined components. HofmannEngineering has extensive experience in precision machining and offer efficientproduction services backed by ISO 9001:2008 and AS9100 compliant qualitymanagement systems. Bull gears and pinions are manufactured for most makes oflocomotive (GE, Alco etc).

BULL GEARS• Case carburised & shot peened and

ground and / or skived.• Tooth by tooth full contour induction

hardened and ground.• Profile regrinding of old worn bull

gears.

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SPIRAL BEVEL GEARS• Case carburised to 58 – 62 HRc

and precision hard cut to DIN Class 3.• Capacity to manufacture spiral bevel

gearing up to 2m.

PINIONSCase carburised and accurately ground including taper crowning. A shot peened full root radius on our pinions provides a substantial strength increase.

Radii on Corners

Shot peened Polished Root on Radii

Involute ground w ith tip & root relief

Hobbed w ith protuberance cutter

Taper crowned lead

Chrome nickel steel – gas Carburisedcore ref ined






3.0 BOGIES

1.1 MACHINING WHEELSForged w heels finished machined on oneof our 6 CNC vertical borers including multipallet changer.

1.2 MACHINING AXLESAxles manufactured to AAR Standards. Sourcing of forged material, NDT tested and finished machined.

1.3 PRESSING WHEELS ONAXLESControlled pressing of wheels onto axlesusing calibrated press with incorporatedchart recorder for traceability.

2.2 CMM COMPONENT

MEASUREMENTTemperature Controlled Calibration andInspection Facilities, w ith 5 x Co-ordinateMeasuring MachinesPhoto show ing Axle Bearing componentsbeing inspected after machining.

2.3 PORTABE CMM

MEASURMENTPortable Coordinate Measuring Machines(PCMM) & laser trackers used to measuremanufactured components both in thew orkshop and onsite.

2.1 MACHINING LOCOMOTIVEENGINE BLOCKSEngine blocks are precision machinedcomplete on one of our seven floor borers.Insitu line boring w ith our portable lineboring machine is also offered.

3.1 BOGIE FABRICATIONBogie frames can be completely fabricatedusing both certif ied welders & roboticw elding. Full stress relieving also available.

3.2 BOGIE MACHININGThe bogie frames are then precisionmachined on one of our 5 gantry CNCmachining centres.

1.0 MANUFACTURE & ASSEMBLY OF WHEELS & AXLES

2.0 RAIL COMPONENTS

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PORTABLE MACHINE

TOOLS

- 63 -

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B O R I N G

F A C I N G

W E L D I N G

• LINE BORING

• FACING

• DRILLING

• ID WELDING

• TURNING

• KEYWAY

• CUTTING

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MK2 PORTABLE LINE BORING MACHINE KIT• Line bore up to 1000mm dia x 6000mm • in length @ up to 240rpm• Suitable for, Boring, Facing, Drilling and • when used with optional attachments can • perform all the following tasks.

WELDING ATTACHMENT• Contains a Millar Welder with inverter arccontrol technology.

• Weld bores from 25mm to 1000mm• Storage box contains extension nozzles • and special welding bars.

MACHINING CENTER• Table area of 1500mm X 1200mm• Converts the line boring machine into a • horizontal borer.• Ideal for repetition work.

FLANGE FACER• Adjustable feed rate from 0.1mm/rev up • to 0.7mm/rev (Gramophone finish).• Faces from 160mm dia to 500mm dia.

FACING HEADS• 180mm or 230mm dia facing head with • variable feed. • 600mm Maximum facing dia 1000mm• with optional tool holder.

TAPER BORING HEAD• Suitable for Boring and Facing.• Universal tool for difficult work.• Ideal for larger diameters.

KEY WAY MILLER• A valuable tool for both manufacturing • and maintenance operations.• Can cut new keyways without the need to • disassemble gearboxes, drive shafts etc.

ORBITAL LATHE• Complete kit to turn up to 1000mm dia x • 3000mm lg.• Operate at speeds up to 40 rpm.

MICRO BORE TOOL HOLDERS• Complements the Hofmann Portable Line

Boring Machine.

LARGE BORE KITEnables Boring up to 1000mm DIA.

ALIGNMENT GAUGEEssential for accurate support bearing alignment when machining multiple bores.

ONSITE WORKPortable Line Boring Machine in use Onsite.Workshop quality repairs in the field.

TYPICAL APPLICATIONS• Girth gear split lines.

• Gearbox split lines.

• Pressure vessels.

• Hold-dow n bolts.

• Engine blocks.

*ANY LARGE BOLTING APPLICATION*

HOFNUTS ENABLE YOU TO:

REMOVES THE NEED TO USE:

HOFNUT

THE HIGH TENSION BOLTING

SOLUTION

• Tighten large nuts with hand wrenches.

• Tighten split joints

accurately to the correct tension.

• Minimal space

requirements.

BO

LT T

EN

SIO

N

• Hydraulic tensioning. • Crane wrenches. • Other cumbersome

methods of tightening.

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STOCKED BLANKSFOR QUICK DELIVERYHofmann Engineering holds in stock arange of pre-machined billets to minimiselead time in the production of acustomer’s specif ic requirements. Theseblanks can accommodate any size and/orpitch betw een 30mm and 80mm and areavailable in both grades.

MIS-ALIGNMENT SOLUTIONSSPHERICAL SEATSHave a mis-aligned bolting face? The useof spherical seats allows the tensioning ofbolts that may be out of alignment,ensuring that your equipment remainstensioned securely. The spherical seatscan withstand more than tw ice the forcethat can be exerted by a fully tensionedHofNut and still maintain their originalstructural integrity.

For your particular HofNut sizing or application

requirements contact us as below.

OD Thick Size (mm)Number

of bolts

Standard

Torque (Nm)

M24 x 3.0P 43 25 6 8 15

M30 x 3.5P 53 29 8 6 37

M36 x 4.0P 66 37 10 6 67

M42 x 4.5P 75 37 10 8 69

M48 x 5.0P 85 45 12 8 110

M56 x 5.5P 100 45 12 8 133

M64 x 6.0P 113 61 16 8 265

M72 x 6.0P 119 64 16 8 316

M80 x 6.0P 132 64 16 12 292

M90 x 6.0P 145 66 16 16 284


of bolts

Standard

Torque (Nm)

1-3/8" x 6TPI 63 37 8 6 66

1-1/2" x 6TPI 69 37 8 8 60

1-3/4" x 5TPI 79 44 10 8 101

2" x 4.5TPI 92 47 12 8 139

2-1/4" x 4.5TPI 100 48 12 8 155

2-1/2" x 4TPI 113 61 16 8 280

2-3/4" x 4TPI 119 62 16 8 316

3" x 4TPI 132 62 16 12 278


of bolts

Standard

Torque (Nm)

M30 x 3.5P 53 29 8 8 37

M36 x 4.0P 66 37 10 8 69

M42 x 4.5P 75 37 10 12 64

M48 x 5.0P 85 45 12 10 122

M56 x 5.5P 100 45 12 12 133

M64 x 6.0P 113 61 16 10 289

M72 x 6.0P 119 64 16 12 311

M80 x 6.0P 132 64 16 16 316

M90 x 6.0P 145 66 16 16 316


of bolts

Standard

Torque (Nm)

1-3/8" x 6TPI 63 37 8 8 62

1-1/2" x 6TPI 69 37 8 8 88

1-3/4" x 5TPI 79 44 10 12 101

2" x 4.5TPI 92 47 12 12 117

2-1/4" x 4.5TPI 100 48 12 12 152

2-1/2" x 4TPI 113 61 16 12 234

2-3/4" x 4TPI 119 62 16 12 288

3" x 4TPI 132 62 16 16 261

Standard

Metric

Coars e Pitch

Size

Im perial HofNuts - HSN43.

Standard

Im perial

Coars e Pitch

(UNC)

Size Jacking Bolts

Metric HofNuts - HSN41.

Size

Im perial HofNuts - HSN41.

Jacking Bolts

Jacking Bolts

Jacking Bolts

Metric HofNuts - HSN43.

Standard

Metric

Coars e Pitch

Standard

Im perial

Coars e Pitch

Size

GRADE HSN 41STANDARDThe HSN 41 HofNuts areused for general mechanicalapplications. These nuts arestandard on the split lines ofour girth gears, andcommonly used on new lymanufactured andrefurbished gearboxes. Arange of sizes are kept instock for quick delivery.

BOLTING LUBRICATIONFor ease of lubrication, each set ofHofNuts comes w ith a tube of 46MR401lubricant for use on the jacking boltthreads and between the tips and thew asher.

GRADE HSN 43HIGH TENSIONFor high tension applications,we recommend our HSN 43grade HofNuts, which aremanufactured from a highergrade of steel and containmore jacking bolts. The 43series can apply up to 50%more force to a split linewhen used with anappropriately rated bolt.

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HOFMANN ANGLE ISOLATION VALVES IN OPERATIONRemote “Air” operated system to open /close and isolate slurry anglevalves. This proven system has a safety and ergonomic advantageby removing operators from line of fire. Can also operate multiplevalves simultaneously from a control box. Equal opportunity productmade easy and simple to operate. Grinding seat made easy.

Before After

DRAIN VALVES MADE EASY TO OPERATEPower operating device fitted to a manual valve can be operatedusing a suitable torque multiplier. Valves can be opened and closedfrom 2 directions, difficult to operate valves facing the ground hasbeen made easy. Through advanced gearing it produces three timesinput torque to open and break through built up scale. Fully testedand patented product.- 67 -

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VALVE&

PUMP

Hofmann Angle Slurry Valves

Power & Remote

Manual Valves fitted with power devices to

remove hammering and injury to operators

High Chrome Products

Replacement Pump Parts




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IN HOUSE ASSEMBLYSlurry valves fully manufactured,Assembled and Hydrostatically tested inhouse for Local and International Aluminarefineries for over 35 Years. We have anexperienced team to manage largeprojects.

VOLUME MANUFACTURESlurry valves manufactured for an overseasexpansion.• We can manufacture from single valves to

thousands in our facility.

VALVES FOR EXPORTHofmann Engineering can organisepackaging and shipping by Air or Oceanfreight to your required destination.

PUMP REPLACEMENT PARTS - HIGH CHROME IRON – 27% to 35% Cr ( 60 Rc Hardness )Hofmann Engineering manufactures and product improves standard Pump Parts that w ould suit your individual application. Productimprovements are carried out in conjunction w ithsite reports and details of application. Threads machined in hardened parent material

HIGH CHROME IRON SPOOLSFabricated spools w ith high chrome iron liners

HIGH CHROME IRON VALVESFabricated valve bodies w ith high chrome liners

CERAMIC LINED VALVES CHECK VALVES

SPECTACLE (GATE) VALVES (CL150)Hydraulic operated valves

Sizes from 250NB to 650NB

CRUSHER OVERHAULSHofmann Engineering provides a complete Factory Crusher Rebuild Service. Rebuilds to “as new”condition w ith the offer of product improvements to increase reliability. We also carry out OnsiteRepairs, Installations, Commissioning and Inspection Services duringplant shutdow ns.

CRUSHERREPAIRS

ANDSERVICES

OVERHAULSREPAIRS

SITE SERVICINGSITE INSPECTION

REPLACEMENT PARTS

GYRATORY CRUSHERSPRIMARY•SECONDARY•TERTIARY

• ALLIS CHALMERS

• FULLER TRAYLOR

• JACQUES

• KAWASAKI

• METSO MINERALS

• KOBE

• NORDBERG

• SANDVIK

• SYMONS

JAW CRUSHERS• ALLIS CHALMERS

• JACQUES

• KUE KEN

• METSO MINERALS

• NORDBERG

• WESSERHUTTE

IMPACT CRUSHERS & SPECIALS• Hofmann Impact Crusher.• Hofmann Mobile Crusher.

MINERAL SIZERSWe can provide the follow ing series:• Replacement product improved

components for MMD & ABON sizers.• Gearboxes.• Sizer teeth.- 69 -

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WELD PREPARATION• Crack machined out.• Weld prep machined to generate

alignment datums and to suit the sub arcprocess.

WELDING MANAGEMENT• We have in-house welding metallurgists

to develop weld procedures for thesedemanding & challenging jobs.

• Submerged arc w elding.

POST HEAT TREATMENTOn completion of welding, the entire shaftis stress relieved in a purpose built oventhat allows the shaft to be rotatingthroughout the process.

WELDINGAll weld repairs are monitored throughoutthe process. This enables HofmannEngineering to fully back challengingrepairs such as cracked or brokenadjustment rings.

MACHININGAll items are finish machined to OEMspecif ications. Threads are machinedusing a 5-axis vertical borer to ensurepitching accuracy.

ASSEMBLY Components can be partially or fullyassembled to reduce downtime duringcomponent changeouts.

SUPPLY OF BEVEL GEARSSupplied to AGMA 10 quality, either;• Quench & tempered to 360 BHN.• Induction Hardened to 56 HRC.• Case Carburised to 60 HRC.

SPECIAL REQUIREMENTSHofmann Engineering w ill develop & manufacture Special Crushers to meet your specific product or customise your existing equipment to suit your specific needs.

SITE & BREAKDOWN SERVICEExperienced Site Services team forinstallation, site inspections andcommissioning for planned or unforeseenshut dow ns.

CRACKED & WORN MAIN SHAFT REPAIRSHofmann Engineering can w eld repair Crusher Main Shafts that OEM’s consider irreparable or w here a replacement is not readily available.

Hofmann Engineering can manufacture new shafts to suit all types and makes of crushers.

WORKSHOP & SITE SERVICES PROVIDING MINESITES WITH THE COMPLETE PACKAGE

COMPONENT REBUILDS: LOCKING & ADJUSTMENT RINGS, HEADS & BOWLS

Position of Weld repaired crack.

NEW SECTION READY FOR WELDING

Full contour induction hardened case.

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HIGH PRESSURE GRINDING ROLLS

(HPGR)

Replacement Parts & Service Including Gearboxes for:

Polysius

KHD

Koppern

Citic

FLS

& Rolls Crushers

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Qu ality Assurance accreditation by Lloyds complements our total quality cu lture.


- 71 -

Hofmann Engineering can offer the following options for Edge protection

Tungsten Carbide blocks with bolt on hard faced retaining clamp plates

(Patent No: 2011301142)The solid tungsten carbide edgeprotection blocks are individually clampedand can’t break off, avoiding acceleratedwear. In the unlikely event of damage,individual b locks or clamp platessegments are easily replaced insitu.

Interchangeable Hard Faced clamp plates

Inspired by Hofmann Engineering’s bolton solid tungsten carbide edgeprotection, Hofmann Engineering’s bolton hard facing segments provide a costeffective a lternative to the solid tungstencarbide edge block solution. Withprimary and secondary carbides in atungsten matrix the segments are highlywear resistant and allow easyreplacement insitu in the unlikely event ofdamage.

A ONE STOP SHOP FOR HPGR MANUFACTURE & SERVICES

Replacement Tyre Options:NEW: Forged high tensile steel tyre, redesigned stud pattern and grade to suit application.

RE-SIZED: Existing tyre, reduced diameter, re-design.

REFURBISHED TO “AS NEW”: Weld O/D to original size, re-design.

Hard Facing overlay

Wear Resistant Steel Segments

Hofmann Engineering offers tailored and improved stud lining tyre designs to suit the ore type, feed and operating conditions. Implementation of varying grades and geometrical

configurations of carbide across the face of the roll also helps eliminate bath tub effect issues.

Stud breakage and chipping effects are addressed by the specific metallurgical, process and design capabilities of Hofmann Engineering.

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Complete design, new manufacture and refurbishment of p lanetary gearboxes for HPGRs. Component part numbers cross referenced against OEM gearboxes.

Above: Hofmann refurbished P2SA-38 (2800kw) HPGR Gearbox under load test.

EXTENSIVE WORKSHOP CAPABILITIES:

200T lifting capacity, 4 stress relieving furnaces and over a dozen vertical and floor borers. In addition purpose built submerged arc welding, bearing refurbishment and stud extraction machines form Hofmann’s HPGR manufacturing arsenal.

HOFMANN HPGR FIELD-SERVICE

The Hofmann HPGR Service Teamis able to provide skilled manpowerat all leve ls, to meet the customersrequirements all over the world365 days a year. The range of sitestaff specialists covers all areas,from mechanical insta llat ion,hydraulic and electrical specialiststo complete site supervision. Theseteams manage complete HPGRInstallat ions, Gearbox Monitoring &Refurbishment Service, RollerChange-Out and machinecommissioning as well as completemachine inspection, conditionmonitoring, insitu repair andoverhauling.

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UNDERGROUNDMINING

PRODUCT IMPROVEDAFTERMARKET PARTS

FOR

CATERPILLARJOY GLOBAL

ATLAS COPCOSANDVIK

MACHINES

- 73 -

Drive Sprockets

• ‘HofCARB’ case hardening for sprokets to a Hardness of 60-62HRc. Process introduces carbide molecules into the martensitic microstructure to increase wear resistance and reduce surface fatigue. • Upgraded 18CrNiMo7 material used.

Conveyor Links• Upgraded heavier pins offers longer

service life.• Offered in various pitch lengths to suit

Crawler pads

• Upgraded material used• Both spline ends are

induction hardened to improve torsional fatigue resistance.

Continuous Miner parts

Hofmann Engineering now offers superior product improved parts for underground mining machineries that are completely interchangeable to OEM parts.

Cutter Drums and Picks

Quill Shafts

• Offered as “new” or “Repair” units.

• Upgraded Picks to improve bonding between carbide and steel.

• Offered as forged construction • Optional induction Hardening availableTo suit tougher ore conditions.

JOEST JR-606 EXCITER GEARBOX• As-received by Hofmann Engineering for repair.• All parts have been re-engineered w ith

improvements to increase the service life.

LUDOWICI LE150 EXCITER GEARBOX• Refurbished by Hofmann Engineering prior to

being prepared for dispatch.

FULL LOAD TEST BEDTesting on test bed w here Vibration Analysis, temperature reading and oil samples are taken after f inal assembly

PRODUCT IMPROVEMENTS• Hofmann Engineering manufactured Case

Hardened and Ground Gears AGMA 10which replace the original through hardenedgears. This will increase service life andreduce the build up of metal contaminants.

• SCHENCK SLD 4385 Exciter Mounting Beamre-engineering by Hofmann Engineering w ithdesign improvements

• Galvanized / Painted w ith rubber coating• Improved material properties• Long cycle stress relieve• Welds dressed & shot peened

• Design improvements to Exciter Beam,Side/Cross Beams w ill remove potential crackinitiation sites to improve crack resistance ofthe beam, extending service life andreducingplant downtime

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VIBRATING SCREENS

REPLACEMENT PARTS &SERVICE

Including Exciter Gearboxes

SchenckMetso

LudowiciJoest

Thyssen Krupp

- 74 -

Hofmann Engineering have many years of experience refurbishing and manufacturing awide range of Vibration Screen components and exciter gearboxes.

Galv anized with rubber coating

Welds dressed & shot peened

Improv ed material & long cy cle stress reliev e

COARSE & FINE SEED DISCFILTER MANUFACTUREto the design of: • BOKELA• POSEIDON

CURRENT END USERS:

• ALCAN GOVE• ALCOA AUSTRALIA• WORSLEY ALUMINA

• GUINEA• BMA (Saraji)• NALCO (India)

SUPPLY OF SPARE PARTSfor all makes:

• DISC SECTORS• BARRELS• CONTROL HEADS

• BEARING HOUSINGS• GEARBOXES• AGITATORS SITE INSTALLATION & SERVICE

DISCVACUUM FILTERS

SAVE THIS AS NEW DOCUMENT

- 75 -

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WELDING/FABRICATIONClose supervision ensures accuracy ofthe fabrication. Weld procedures andwelding processes are managed by ourexperienced team.

INLINE TESTINGNDT testing of welds, dimensionalinspections and leak tests carried out atvarious stages during the manufacturingprocess.

SURFACE TREATMENTStrict adherence to sand blasting andpainting procedures to ensure surfacetreatment w ill w ithstand the onsiteenvironment

MACHININGAll machining is able to be carried out in-house using a variety of conventional andmodern NC machines.

INSPECTIONAll components are inspected during andafter the manufacturing process. Criticalcomponents are jig tested for compliance

PRESSURE PARTSManufacture of all pressure parts is to thespecif ied Australian Standard andrelevant w elding codes.

ASSEMBLYAll f ilters are assembled and dry run.Bearing clearances, axial and radial runouts along w ith disc sector clearances arechecked as part of this process.

FACILITIES We are fortunate to have a number of large assembly bays w here this type of w ork can be carried out. This allow s more than 1 unit to be w orked on at a time.

PACKINGThe filter components are packed fortransportation either on flat racks,containers or directly onto prime movers.All machined surfaces are protected anda heavy emphasis is placed on securingthe items for sea freight.

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FIN STABILISER MANUFACTURE AND REFURBISHMENT

RIGHT: JOINT STRIKE FIGHTER PRODUCTION TOOLING

MILITARY APC CHASSIS

WING FLAPERON TOOL

Hofmann Engineering, a globally recognised engineering solutions provider to thedefence industry offers a range of specialised tooling to support the manufacture ofmajor components and sub assemblies for airforce, army and naval assets.

Our full turnkey tooling service incorporates:

• Engineering design

• Manufacture

• Fabrication

• Assembly

• Accredited testing and installation

• Electro/Mechanical site service

CAPABILITIES

DEFENCE

Military Naval

SubmarinesArmoured Vehicles

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PROPULSION SHAFT MANUFACTURE AND REFURBISHMENT

AEROSPACE COMPONENTRY

PROJECT EXPERIENCE

AIR• BAE Systems - Hawk Horizontal Stabilizer Skins

- Hawk Weapons Pylons

• C130H - Inboard Flap Assembly Jigs

• DRCACS - R & D Activity

• F/A – 18 - Horizontal Stabilizer Tooling

• MRTT - Tooling Validation

• Nimrod - Weapons Pylon Assembly Jigs

• P3 Orion - Nacelles

- Replacement Floor Panels

- Tooling

• 737 Wedgetail - Wing Tip Radome Tool

LAND• BAE Systems – M113 APC & Armoured Hull upgrades

• Thales – Bushmaster

SEA• Anzac Frigates – Machined Components

• Collins Class Submarine – Machined Components/Propeller

Shafts and Generator Rebuilds

• Jindivik – Jig Refurbishments

• Mine Hunter Vessels – Machined Components

• Nulka – Decoy System Components

• Amphibious and Afloat support – gearbox repairs

ACCREDITATION• AS9100 Aerospace Standard – Hofmann Cheltenham,

Melbourne (formerly Metaltec).

• ISO9001 accreditation for Perth and Bendigo

Manufacturing sites.

Hofmann Engineering is an approved supplier to:

• BAE Systems-Australia

• BAE Systems-UK

• GE Rolls-Royce Fighter Engine Team

• Australian Submarine Corp

• Rolls Royce Australia Services Pty Ltd

• Thales • Boeing • DMO

• Raytheon

• Naval Ship Management

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- 79 -

CAPABILITIESOur full turnkey tooling service incorporates:• Engineering design.• Manufacture• Fabrication• Assembly• Accredited testing and

installation.

DEMONSTRATED SUCCESSHofmann Metaltec has been anaerospace industry supplier for over 25 years. Our solutions for major commercial and military aircraft programs include:• Project management• Lay-up mandrels• Bonding fixtures• Assembly jigs and fixtures• Mould tools for composite

manufacture• Parts manufacture and

assembly• Cutting tools for alloys and

composites• Machining of exotic materials

including Titanium, Inconel, Invar 36 and Aluminium

• Inspection and metrology

Hofmann Metaltec, a globally recognised engineering solutionsprovider to the aerospace industry offers a range of specialisedtooling to support the manufacture of metallic and compositecomponents and aero structures, together with the machining ofcomposite and metallic components.

AEROSPACE

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ACCREDITATIONHofmann Metaltec is an approved supplier to:

• Airbus

• BAE systems

• Boeing

• GE Rolls-Royce Fighter Engine Team

PROJECT EXPERIENCE

Commercial aircraftB787 – Outboard Flap

B777 – Rudder (National Award Winner)

B777 – Elevator (National Award Winner)

B777 – Trim Tab (National Award Winner)

B767 – Slats

B757 – Rudder Hinges

B747-8 – Krueger Panel Holding Fixtures

B737 – Krueger Flaps

A380 – Winglets

A340 – Winglets

A330/340 – Floor Beams

A330/340 – Landing Gear Doors

Military AircraftBAE Hawk – Tailplane Skins

BAE Hawk – Weapons Pylons

C130J – Inboard Flaps

F/A – 18 – Wing Skins

P3 Orion Nacelles and Centre Fuselage Floor

beams Nimrod Wedgetail Winglet

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CUTTING TOOLS

Special purpose cutting tools and holders are designed and manufactured to thehighest level of precision to meet customer needs including reduced cycle time,reduced cost and improved quality.

We provide:• Design and manufacture of special purpose tooling including:

• Solid carbide & high speed steel form tools.• Special pocketed cutting tool holders suitable for

indexable carbide inserts.• Brazed carbide form cutting tools.• Special tool holders including arbours & mandrels.• Special form insert manufacture & service.• Form roller and sintered component finishing.

• Tooling and cycle optimisation to maximise production efficiency• Fast and efficient service utilising our multiple machining capacity

CUTTING TOOL SERVICE

CAPABILITIESSpecial purpose tooling design and manufacture

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SPECIALISED CUTTING TOOLS

Our ANCA 5 axis CNC cutting tool grinding machines are equippedwith ANCA’s iView camera system. ANCA iView allows componentsto be measured while they are still in the machine to ensure perfectaccuracy, whether it is a complex form tool, accurate ball nose cutteror profiled roller.

All machines are networked to allow tools to be programmedand tested on ANCA’s state of the art tool grinding simulationsoftware, prior to being loaded onto any of the machinesallowing more efficient & accurate tool grinding.

Complex form tools with high accuracy areproduced using our grinding technology andtechniques.

Cutters can be PVD coated to suit applicationneeds.

Tooling can also be reconditioned to theoriginal manufacturer’s specifications toachieve required tool life and cost.

Our 5 axis machining capability covers the manufacture ofcomplex components, tool holders, pocketed tooling andarbours from almost any desired material with highaccuracy.

Along with our CNC cylindrical, Jig & Optical Profilegrinding, form inserts, rollers and components can bemanufactured as desired.

Hofmann Engineering is one of the onlycutting tool service companies in Australiawith a quality system that is aerospaceindustry accredited to AS9100.

STATE OF THE ART TECHNOLOGY

DESIGN AND MANUFACTURE

AEROSPACE ACCREDITED

EXPERIENCED PROFESSIONAL SERVICE

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YOGHURT CUTTING TOOLS THERMO FORM TOOLING

CAN MAKING TOOLING FOOD & BEVERAGE CAN TOOLING

Z BARS RE-ENGINEERING SERVICES

FOOD PACKAGING

Food & Beverage Canning & Packaging

Cutting Tools Support Centre

This image cannot currently be displayed.

Hofmann Metaltec “Foodpack/Can Making” Tooling support centre offers worldclass manufacturing capability for Food Packaging and Can Makers toolingrequirements. We provide a single source fully managed service for themanufacture of precision tooling including die maintenance and refurbishment, wealso offer re-engineering services. Our purpose built climate controlledmanufacturing facility and specialist team of highly skilled tradesmen ensure wemeet the stringent tolerances precision and high standards required for theindustry. Our dedicated business ensures shorter lead times, fast delivery andrapid response times to all breakdown and maintenance work.

MANUFACTURE

• All Canmakers’ tooling requirements

• Canning and end making tooling

• New end making double dies

• Seamer tooling - seaming chucks

& seaming roller

REFURBISHMENT

• Canmakers’ die sets

• Hassia and Erca Tooling / Form Fill

& Seal

RE-ENGINEERING SERVICES

EMERGENCY BREAKDOWNS

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YOGHURT CUTTING TOOLS PRODUCT IMPROVED - TOOL STROKE LIFE DOUBLED

EQUIPMENT RANGE

CAD/CAM DESIGN SOFTWARE INCLUDING:

• Catia v5

• Unigraphics NX4-6

• ProE

A RANGE OF PRECISION 2, 3 AND 5 AXIS NC MACHINES

INSPECTION & METROLOGY LABORATORY INCLUDING:

• Co-ordinate measuring machines (3)

• Laser tracker (1)

• Climate Controlled Environment

• Expertise in precision toolmaking

• Excellent knowledge of yoghurt cutting tools

• World class quality and workmanship

• 2.5 times more price competitive than OEM

• 10 to 12 week lead time on refurbishments

• Fast quotation process

• Technical support

DEMONSTRATED SUCCESS

Hofmann Metaltec has a vast experience inproviding engineered solutions to various foodpackaging companies.

CUTTING TOOLS SUPPORT CENTREHofmann Engineering’s cutting tools support centre offers worldclass tool making capabilities and provides a single source fullymanaged service to customers.

HOFMANN ENGINEERING CUTTING TOOLS SUPPORT CENTRE CAN OFFER:

CERAMIC DOMER PRESSURE RING DIE FOR FORMING BOTTOM END OF CAN

HIGH PRECISION TAB DIE TOOL ENHANCED LIFE USING HIGH PERFORMANCE COATINGS

PRODUCT IMPROVED TAB DIESTITANIUM COATED FOR LONGER SERVICE LIFE

YOGHURT CUTTING TOOL MATRIX

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SOLAR PANEL FRAMES

A RANGE OF PRESSED

COMPONENTS

PRESSINGHofmann Metaltec offers well-equipped and fully independent production pressing facilities with the capability for both short run batch and high volume production.

PRESSSHOP

The Metaltec facility specialises in:

• Automotive component pressing

• Supplies to whitegoods and general manufacturing sectors

• Deep drawing of steel, stainless steel, aluminiumand copper

• Post press operations such as spot and projection welding, machining and assembly.

Hofmann Metaltec’s pressingcapabilities include single anddouble acting presses rangingfrom 60-700 tonnes, cateringfor dies up to 10 tonnes, withoff-coil capability. Our broadrange of presses allowproduction flexibility andresponsiveness for urgentproduction requirements.

AUTOMOTIVE COMPONENTS INCLUDING 4WD BULLBAR

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+61 8 9279 5522+61 8 9279 9386

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+61 8 9279 5522+61 8 9279 9386

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CAPABILITIES

• VERSON – 700 TONNE

• Size of bed: 2740mm x 1370mm

• Shut height: 2100mm, single action

• BRITISH CLEARING – 500 TONNE



DESIGN• Progressive and deep drawing press metal tooling. • Jigs and Fixtures• Turnkey Projects

MANUFACTURING• Press Metal Stamping• Duplex or Triplex dies for small batch runs• Off coil stamping for large production runs. • Deep drawing expertise in steel, stainless steel, aluminium and

copper.• Coil handling capacity up to 3 tonnes with feeders to 1M in width.

QUALITY• CMM Reporting• PPAP Submissions.(Pre Production Approval Process)• ISO Accredited AS9100 and ISO9001

• DANLY – 500 TONNE



• JIANGSU YANGLI – 500 TONNE



PRESS SPECIFICATIONS

ABOVE: SMELTER POT DOOR COVERS WITH HINGES AND LATCHES WELDED ON

LEFT: COIL FED PRESS

RIGHT: A RANGE OF MATERIALS; COPPER, ALUMINIUM, STEEL PRESSINGS

REPRESENTATIVES

&

HEAD OFFICE LOCATION MAP

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C = Hofmann Engineering Pty LtdB = Perth Domestic AirportD = Perth International Airport

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Head Office

AIRPORT DIRECTIONS TO HOFMANN ENGINEERING (HEAD OFFICE)

WORLD REPRESENTATIVES

Please see www.hofmannengineering.com for more information regarding agents and representatives

+61 8 9279 5522+61 8 9279 9386

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Hofmann Manufacturing SitesHofmann Land & OfficesHofmann Agents

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WORKSHOP CAPACITIES

TURNING 4,100mm diam x 10,000mm long / 1,870mm diam x 35,000mm long

GRINDING Cylindrical Roll Grinding to 1,000mm dia x 10,000mm lg

BOR ING – HORIZO NTAL 12,000 x 3,900 x 2,000 (WA) /18,000 x 5,000 x 1,500 (VIC)

BOR ING – VERTICA L 15,000mm / 9,200mm / 7,000mm diameter

HIGH VOL UME PRO DUC TION MAC HINERY 7 units of 5-axis CNC Machining Centres up to 18,000mm x 5,000mmGEAR CUTTING

Climate controlled environment. Accuracy to DIN 5 (AGMA 12)

Gears External 15,000mm dia x 2,500mm face width (3 units ; 15m, 14m, 11m diam)

Gears Internal 15,000mm OD x 500mm face width

Worms & worm gears 4,000mm dia x 30 module

Bevel gears; Spiral/Slew 4,000mm dia x 310mm face width (Din 3 Hard cutting)

Sprockets 15,000mm dia

Crown Gear Couplings 2,000mm dia x 1,000mm face width

Double helical gears 14,000mm dia x 2,500mm face width

Maag CNC 3 off SH 500 with internal hard cutting 5,000mm dia x 900mm face

GEAR GR IND ING

Climate controlled environment Accuracy to DIN 2 (AGMA 15)

Hofler CNC Form Grinder (internal & external) Four units to 2,400mm diam x 1,500mm face width

GEAR INSPECTION

Climate controlled environment Klingelnberg PSFU 2,500mm dia x 1,000 face width

3D Co-ordinate measuring machine

with gear lead involute and pitch software 15,000mm dia x 1,000mm face width

3 units Portable CMM with Gear Inspection

FINE INS PECTION

Climate controlled environment. Hexagon-Leitz Co-Ordinate Measuring Machine; MPEP (ISO 10360-2): 2.0μm

Envelope dimensions; 3,000mm x 1,500mm x 1,000mm plus 16T rotary table

DESIGN & ENGINEERING SER VICES CAD, CAM & FEA applications; SolidWorks & KISSsoft Gear Design

HEAT TR EATMENT Full metallurgical laboratory for Failure Analysis

Atmosphere controlled: Gas carburising:

Total of 15 furnaces covering all aspects - Pit furnaces and fluidised bed. 1,900mm dia x 5,000mm long.

of modern heat treatment. Induction hardening: - Tooth by tooth induction hardening machine. 5 off machines

Gears, pinions, track pads. Full contour profile up to 15,000mm dia

Quench and tempering:

- Oil tank 30,000L 1,900mm x 5,000mm long

- Water/polymer quench

Nitriding:

- Carbo nitriding Furnace 900mm dia x 1,800mm

- Nitro carburising Furnace 900mm dia x 1,800mm

Tool Steels :

- Fluidised bed 1200°C Furnace 900mm dia x 1,800mm

Tempering Furnace 6,000mm dia x 3,000mm

Stress relieving - Gas Furnace 15,000mm x 15,000mm wide

Stress relieving - Electric Furnace 12,000mm dia x 2,000mm

Marquench

Shot peening

Sand blasting

FABR IC ATION / WELDING Fabricated gears, transmission boxes and mining equipment - 200 tonnes.

Plate Rolls 6,000T, 3,650mm width x 220mm thick

4,000T, 3,200mm width x 150mm thick

PRODUCT S UPPORT A ND F IELD SER VICE

LUBR IC ATION AND CO NDITION MONITORING

QUA LITY A SSURA NCE Certified to ISO9001 and AS9100 by Lloyds

LIFTING and HANDLING 26 Overhead Gantry Cranes to 200 tonnes

2 Yard Cranes & Straddle Carrier

5 Forklifts

FACTO RY S PACE Over 60,000m2 (approx. 15 acres) under-roof across four facilitiesThe above capacities are indicative only, please contact us with your specific requirements.

Information supplied is subject to change without notice.

MAXIMUM CAP ACI T Y

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