Product Description
Product Parameters
The material is low carbon or alloy steel,such as ZG270-500,ZG42CrMo,ZG35Mn and so on.
Material:ZG25CrNiMo
| Steel Grade | Chemical Composition % | |||||||
| C | Si | Mn | Cr | Ni | Mo | S | P | |
| ZG25CrNiMo | 0.25-0.30 | 0.20-0.40 | 0.70-0.90 | 0.40-0.70 | 0.40-0.70 | 0.15-0.25 | <=0.571 | <=0.571 |
| ZG30CrMo | 0.26-0.33 | 0.17-0.37 | 0.40-0.70 | 0.80-1.10 | – | 0.15-0.25 | <=0.571 | <=0.571 |
| ZG35CrMo | 0.32-0.40 | 0.17-0.37 | 0.40-0.70 | 0.80-1.10 | – | 0.15-0.25 | <=0.571 | <=0.571 |
| Standard |
Yield Strength Rp0.2 /MPa |
Tensile Strength
Rb / MPa |
Elogation
A / % |
Reduction of Area Z/ % |
| 60K | ≥414 | ≥586 | ≥18 | ≥35 |
| 75K | ≥517 | ≥655 | ≥18 | ≥35 |
| 80K | 585-660 | ≥725 | ≥18 | ≥35 |
| Material | C | Si | Mn | P | S |
| ZG270-500 | 0.32-0.40 | 0.20-0.52 | 0.45-0.90 | ≤0.035 | ≤0.035 |
| Material | C | Si | Mn | P | S | Cr | Mo |
| ZG42CrMo | 0.38-0.43 | 0.15-0.35 | 0.75-1.00 | ≤0.035 | ≤0.035 | 0.80-1.10 | 0.15-0.25 |
| Material | C | Si | Mn | P | S |
| ZG35Mn | 0.30-0.40 | 0.60-0.80 | 1.10-1.40 | ≤0.035 | ≤0.035 |
It is up to customers’ requirement.
| Item | Standard |
| Casting Material | EN 15713/EN 10571/BS 3100/DIN 1681/DIN17205 |
| Casting Tolerance in Blank | ISO 8062 CT 13 |
| Size Tolerance | DIN ISO 2768m |
| NDT | ASTM A609 Level 2 or 3 /EN 12680/ASTM E94 Level 2 or 3 |
| Heat Treatment | Normalizing+Tempering+Quenching |
| Hardness | As Required |
Company Profile
Haian CZPT Casting Co.,Ltd. is established in 2003 in CZPT Town.
In 2007,we moved our factory to Sunzhuang town and now we can supply bigger steel castings with max. weight 45 tons.
In 2011,we built a new sand mold maiking workshop with 120 tons refinining CZPT and the max. weight can be 120 tons.
In 2013,we paid more attenion on the castings for shipbuilding and started to supply marine castings for most of domestic famous shipyards.
From 2013 to 2571,we bought more and more machines to strengthen our ability from rough machining to finished machining.
In 2571,we built another new sand mold making workshop for the quick development of market requirement.
Now we monthly supply 6000 tons different castings for different customers of different industry,such as cement mill,shipubuilding,petroleum machinery,rolling mill,forging press and so on.
Prodcution Process
1)Pattern making
We have our own wooden pattern making workshop.
But our company is always busy,
we also have around 10 sub-contractors for pattern making.
They help us for the pattern but will be inspected according to our rules.
We will record for every pattern inspection.
2)Silica or chorme sand cores
We have around 80 technicans for sand core making which is divided into around 10 teams.
Most of the technicans has more than 10 years’ experience.
Most of the sand core is made by silica sand with common sand inside of it.
The common sand will be used repeatly.
For some important position,such as R corner,we will use chorme ore sand.
The outside of the sand core,we will do the painting,burn and clean it.
We will assemble diffrent sand cores together and wait for pouring.
3)Melting and Pouring
We always do the melting after mid-night for cheaper electric charge.
And we normally do pouring in the early morning.
| No. | Equipment Name | Quantity(Set) |
| 1 | 25 tons Electrical Arc Furnace | 1 |
| 2 | 50 tons Intermediate Frequency Furnace | 2 |
| 3 | 120 tons Refining Furnace | 1 |
| 4 | 120 tons VD Furnace | 2 |
Before and after pouring,we will do the chemical compostion test.
4)Cooling
After pouring,we will wait for different time for cooling according to casting’s weight.
| Item | Weight in blank(Metric Tons) | Cooling Time(Hour) |
| 1 | <25 | 48 |
| 2 | >25-40 | 72 |
| 3 | >40-55 | 96 |
| 4 | >55-72 | 120 |
| 5 | >72-96 | 144 |
| 6 | >96-115 | 168 |
| 7 | >115 | 192 |
We have our experience and rules for cooling time.
After cooling,we will shake the casting out of the steel boxes and clean them.
5)Heat Treatment
Normalizing will be 3 days while tempering is 4 days.
We have around 10 sets of heat treatment furnaces.
The biggest 1 is 12m*9m*6m.
It is also the biggest size of castings we can make.
After heat treatment,we will do the mechanical property test.
Our ordinary test block’s size is 230mm*70mm*50mm.
One casting part will min. have 3 pcs test blocks.
We have our testing center and it is approved by CNAS.
6)Draw the line and do the first rough machining
We can do the machining from rough to finished machining.
7)NDT after rough machining
8)Welding repair
We have rich experience for making support rollers and kiln tyres,
then there is no welding for the outside working position.
This is our special technology.
Every year we supply around 400pcs kiln tyres,930pcs support roller,170 sets gear( in 2 halves).
But for some other castings,if we do the welding repair,
we will do the tempering for stress relief later.
All of our welders have the SGS certficate.
9)Shot blasting and grinding
We have a robert grinder.
We have a 120 tons rotary shot blasting table.
10)Final machining
We have a lot of vertical lathes from 2.5m to 10m.
Certifications
We get approval from CNAS for our laboratory.
We also have 9 class certificate,such as ABS,DNV,NK,RINA,KR,CCS,BV and so on.
Packaging & Shipping
We supply a lot of castings for cement mill,rolling mill,shipbuilding and so on.
We can do the packing according to our rules or according to customers’ requirement.
After Sales Service
Normally there is a 12 months quality warantty.
We do at least 3 times NDT:after rough,semi-finished and finished machining.
And also the customer will do the witness during or after finished machining.
If there is also any problem when you receive the castings,
please send us photos and detailed defects,
we will negotiate with you and make a compensation.
A third party inspection before shipment is welcomed.
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Shipping Cost:
Estimated freight per unit. |
To be negotiated|
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| Type: | Chemical Hardening Sand |
|---|---|
| Casting Method: | Directional Crystallization |
| Sand Core Type: | Sodium Silicate Sand Core |
| Samples: |
US$ 20/kg
1 kg(Min.Order) | Order Sample |
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| Customization: |
Available
| Customized Request |
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Helical, Straight-Cut, and Spiral-Bevel Gears
If you are planning to use bevel gears in your machine, you need to understand the differences between Helical, Straight-cut, and Spiral bevel gears. This article will introduce you to these gears, as well as their applications. The article will also discuss the benefits and disadvantages of each type of bevel gear. Once you know the differences, you can choose the right gear for your machine. It is easy to learn about spiral bevel gears.
Spiral bevel gear
Spiral bevel gears play a critical role in the aeronautical transmission system. Their failure can cause devastating accidents. Therefore, accurate detection and fault analysis are necessary for maximizing gear system efficiency. This article will discuss the role of computer aided tooth contact analysis in fault detection and meshing pinion position errors. You can use this method to detect problems in spiral bevel gears. Further, you will learn about its application in other transmission systems.
Spiral bevel gears are designed to mesh the gear teeth more slowly and appropriately. Compared to straight bevel gears, spiral bevel gears are less expensive to manufacture with CNC machining. Spiral bevel gears have a wide range of applications and can even be used to reduce the size of drive shafts and bearings. There are many advantages to spiral bevel gears, but most of them are low-cost.
This type of bevel gear has three basic elements: the pinion-gear pair, the load machine, and the output shaft. Each of these is in torsion. Torsional stiffness accounts for the elasticity of the system. Spiral bevel gears are ideal for applications requiring tight backlash monitoring and high-speed operations. CZPT precision machining and adjustable locknuts reduce backlash and allow for precise adjustments. This reduces maintenance and maximizes drive lifespan.
Spiral bevel gears are useful for both high-speed and low-speed applications. High-speed applications require spiral bevel gears for maximum efficiency and speed. They are also ideal for high-speed and high torque, as they can reduce rpm without affecting the vehicle’s speed. They are also great for transferring power between two shafts. Spiral bevel gears are widely used in automotive gears, construction equipment, and a variety of industrial applications.
Hypoid bevel gear
The Hypoid bevel gear is similar to the spiral bevel gear but differs in the shape of the teeth and pinion. The smallest ratio would result in the lowest gear reduction. A Hypoid bevel gear is very durable and efficient. It can be used in confined spaces and weighs less than an equivalent cylindrical gear. It is also a popular choice for high-torque applications. The Hypoid bevel gear is a good choice for applications requiring a high level of speed and torque.
The Hypoid bevel gear has multiple teeth that mesh with each other at the same time. Because of this, the gear transmits torque with very little noise. This allows it to transfer a higher torque with less noise. However, it must be noted that a Hypoid bevel gear is usually more expensive than a spiral bevel gear. The cost of a Hypoid bevel gear is higher, but its benefits make it a popular choice for some applications.
A Hypoid bevel gear can be made of several types. They may differ in the number of teeth and their spiral angles. In general, the smaller hypoid gear has a larger pinion than its counterpart. This means that the hypoid gear is more efficient and stronger than its bevel cousin. It can even be nearly silent if it is well lubricated. Once you’ve made the decision to get a Hypoid bevel gear, be sure to read up on its benefits.
Another common application for a Hypoid bevel gear is in automobiles. These gears are commonly used in the differential in automobiles and trucks. The torque transfer characteristics of the Hypoid gear system make it an excellent choice for many applications. In addition to maximizing efficiency, Hypoid gears also provide smoothness and efficiency. While some people may argue that a spiral bevel gear set is better, this is not an ideal solution for most automobile assemblies.
Helical bevel gear
Compared to helical worm gears, helical bevel gears have a small, compact housing and are structurally optimized. They can be mounted in various ways and feature double chamber shaft seals. In addition, the diameter of the shaft and flange of a helical bevel gear is comparable to that of a worm gear. The gear box of a helical bevel gear unit can be as small as 1.6 inches, or as large as eight cubic feet.
The main characteristic of helical bevel gears is that the teeth on the driver gear are twisted to the left and the helical arc gears have a similar design. In addition to the backlash, the teeth of bevel gears are twisted in a clockwise and counterclockwise direction, depending on the number of helical bevels in the bevel. It is important to note that the tooth contact of a helical bevel gear will be reduced by about ten to twenty percent if there is no offset between the two gears.
In order to create a helical bevel gear, you need to first define the gear and shaft geometry. Once the geometry has been defined, you can proceed to add bosses and perforations. Then, specify the X-Y plane for both the gear and the shaft. Then, the cross section of the gear will be the basis for the solid created after revolution around the X-axis. This way, you can make sure that your gear will be compatible with the pinion.
The development of CNC machines and additive manufacturing processes has greatly simplified the manufacturing process for helical bevel gears. Today, it is possible to design an unlimited number of bevel gear geometry using high-tech machinery. By utilizing the kinematics of a CNC machine center, you can create an unlimited number of gears with the perfect geometry. In the process, you can make both helical bevel gears and spiral bevel gears.
Straight-cut bevel gear
A straight-cut bevel gear is the easiest to manufacture. The first method of manufacturing a straight bevel gear was to use a planer with an indexing head. Later, more efficient methods of manufacturing straight bevel gears were introduced, such as the Revacycle system and the Coniflex system. The latter method is used by CZPT. Here are some of the main benefits of using a straight-cut bevel gear.
A straight-cut bevel gear is defined by its teeth that intersect at the axis of the gear when extended. Straight-cut bevel gears are usually tapered in thickness, with the outer part being larger than the inner portion. Straight-cut bevel gears exhibit instantaneous lines of contact, and are best suited for low-speed, static-load applications. A common application for straight-cut bevel gears is in the differential systems of automobiles.
After being machined, straight-cut bevel gears undergo heat treatment. Case carburizing produces gears with surfaces of 60-63 Rc. Using this method, the pinion is 3 Rc harder than the gear to equalize wear. Flare hardening, flame hardening, and induction hardening methods are rarely used. Finish machining includes turning the outer and inner diameters and special machining processes.
The teeth of a straight-cut bevel gear experience impact and shock loading. Because the teeth of both gears come into contact abruptly, this leads to excessive noise and vibration. The latter limits the speed and power transmission capacity of the gear. On the other hand, a spiral-cut bevel gear experiences gradual but less-destructive loading. It can be used for high-speed applications, but it should be noted that a spiral-cut bevel gear is more complicated to manufacture.
Spur-cut bevel gear
CZPT stocks bevel gears in spiral and straight tooth configurations, in a range of ratios from 1.5 to five. They are also highly remachinable except for the teeth. Spiral bevel gears have a low helix angle and excellent precision properties. CZPT stock bevel gears are manufactured using state-of-the-art technologies and know-how. Compared with spur-cut gears, these have a longer life span.
To determine the strength and durability of a spur-cut bevel gear, you can calculate its MA (mechanical advantage), surface durability (SD), and tooth number (Nb). These values will vary depending on the design and application environment. You can consult the corresponding guides, white papers, and technical specifications to find the best gear for your needs. In addition, CZPT offers a Supplier Discovery Platform that allows you to discover more than 500,000 suppliers.
Another type of spur gear is the double helical gear. It has both left-hand and right-hand helical teeth. This design balances thrust forces and provides extra gear shear area. Helical gears, on the other hand, feature spiral-cut teeth. While both types of gears may generate significant noise and vibration, helical gears are more efficient for high-speed applications. Spur-cut bevel gears may also cause similar effects.
In addition to diametral pitch, the addendum and dedendum have other important properties. The dedendum is the depth of the teeth below the pitch circle. This diameter is the key to determining the center distance between two spur gears. The radius of each pitch circle is equal to the entire depth of the spur gear. Spur gears often use the addendum and dedendum angles to describe the teeth.
editor by CX 2023-05-24