AGMA-06FTM05-2006.pdf
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1、06FTM05 Development of a Gear Rating Standard - - A Case Study of AGMA 6014- -A06 by: F.C. Uherek, Rexnord Geared Products TECHNICAL PAPER American Gear Manufacturers Association Copyright American Gear Manufacturers Association Provided by IHS under license with AGMA Licensee=Boeing Co/5910770001 N
2、ot for Resale, 07/24/2008 22:56:55 MDTNo reproduction or networking permitted without license from IHS -,-,- Development of a Gear Rating Standard - - A Case Study of AGMA 6014- -A06 Frank C. Uherek, Rexnord Geared Products The statements and opinions contained herein are those of the author and sho
3、uld not be construed as an official action or opinion of the American Gear Manufacturers Association. Abstract The AGMA Mill Gearing committee recently released AGMA 6014 rating gears for grinding mill and kiln service. In the development of this standard, the committee took a different approach to
4、determining the end result of the standard writing process. Through review of previous standards, the reluctance of the user community to support the street version of 6004, performance history for these long life (over 20 years) applications, and extreme size of this type of gearing, the committee
5、achieved consensus on a new rating method derived from 2101 rating practice. A factor comparison between 6014 and 2101 is presented as well as their interaction to explain the goal of the committee to develop a document that reflects actual field experience of operating sets in service. Copyright 20
6、06 American Gear Manufacturers Association 500 Montgomery Street, Suite 350 Alexandria, Virginia, 22314 October, 2006 ISBN: 1-55589-887-4 Copyright American Gear Manufacturers Association Provided by IHS under license with AGMA Licensee=Boeing Co/5910770001 Not for Resale, 07/24/2008 22:56:55 MDTNo
7、reproduction or networking permitted without license from IHS -,-,- 1 Development of a Gear Rating Standard A Case Study of AGMA 6014- -A06 Frank C Uherek, Rexnord Geared Products Introduction The AGMA Mill Gearing committee recently re- leased AGMA 6014 rating gears for grinding mill and kiln servi
8、ce. In the development of this stan- dard,thecommitteetookadifferentapproachtode- termining the end result of the standard writing pro- cess. Through review of previous standards, the reluctance of the user community to support the street version of the in place standard AGMA 6004, performance histo
9、ry for these long life (over 20 years) applications, and extreme size of this typeof gearing, the committee achieved consensus on a new rating method derived from the AGMA 2001 rating practice. A factor by factor comparison be- tween 6014 and 2001 is presented as well as their interaction to explain
10、 the goal of the committee to developadocumentthatreflectsactualfieldexperi- ence of operating sets in service. Explanation of gearing for grinding mills and kilns Grinding mill and kiln service are an unusual instal- lation for gearing when compared to traditional en- closed gear drive installation
11、s. But this application hasbeenutilizedforovereightyyears.Thegrinding process, more accurately termed a tumbling pro- cess, uses horizontal rotating cylinders thatcontain grinding media and the material to be broken. The material moves up the wall of the drum until gravity overcomescentrifugalforces
12、anditdropstothebot- tomofthedrumtocollidewiththeremainingmateri- al. This breaks up the particles and reduces their size. Kilns rotate at far slower speeds to enable evenfiringoftheircontents.Powerrangesfrom100 to20000HP(75to15000kW)ineithersingleordual motor configurations. The pinion is mounted on
13、 pillow blocks driven by a low speed motor or a motor and enclosed reducer. Formillapplications,thegearismountedonthemill using a flange bolted connection. See figure 1 for one type of installation. For a kiln, various types of springplatesareused.Boththecenterdistanceand alignmentareadjustableeithe
14、r byshimming thepil- low blocks or moving the mill. Lubricant is typically either high viscosity oil (1260 cSt 100 C) sprayedonthegearin15minuteintervalsoralower viscosityoilorgreaseproductsprayedonthepinion every few minutes. Alternately, lubrication can be applied by continuous spray or dip immers
15、ion methods. Figure 1. Grinding Mill Installation Gearsizescanrangeupto46feet(14meters)indi- ameterwith facewidths approaching50 inches(1.2 meters). Typical tooth sizes range from 20 to 40 module (1.25 DP to 0.64 DP). Single stage reduc- tion gears range from 8:1 to as much as 20:1. Gear materials a
16、re typically through hardened cast steel, fabricated rolled steel or spheroidal graphic iron. Pinions are carburized, induction hardened, or through hardened steels. For small installations, ei- ther a one or two piece design is used with the split joints located in the root of a tooth. Four piece d
17、e- signs are also made when weightor pouringcapac- ity becomes an issue. How to Develop a Gear Standard Thedailylifeofagearengineerinvolvesmanyactiv- ities. A large amount of time is spent designing gears sets for specific applications and comparing these designs to standard practice. The engineer n
18、eeds to balance reliability, manufacturing,installa- tion, and cost against “good design practice”. One indicator of good designpractice isan industrygear ratingstandard.Thisisaconsensusdriven document that strives to use a best practice com- mensurate with material capacity, installation skill, lub
19、rication,quality,andanalysistoindicatehowwell a specific design meets the industry and end user expectations. Copyright American Gear Manufacturers Association Provided by IHS under license with AGMA Licensee=Boeing Co/5910770001 Not for Resale, 07/24/2008 22:56:55 MDTNo reproduction or networking p
20、ermitted without license from IHS -,-,- 2 To develop a gear rating standard, a collection of text and formulas one needs to begin the process with the key formula: Purpose = n i=1 People Discussion M j=1 ExamplesText = 2 Ballot = Document Thecreationofastandarddoesnotoccurinavacu- um.Onemusthaveacle
21、arpurposeinmindastothe outcome of the process during development. In many cases, standards committees look at the cur- rent edition document and update it to account for theworkofothertechnicalcommittees,newdiscov- eries in material and lubrication, better manufactur- ing and tolerance control, and
22、results of the ISO “methodA”ratingpractice,i.e.fullscaletesting,and field experience. AGMA has worked extensively to eliminate the dif- ferences in North American, European, and Asian rating practices through its work with ISO Technical Committee 60. A gear should rate the same when using the same m
23、aterials, processing, and accep- tance criteria - regardless of the location of manufacturer.Standardshavebeenupdatedworld- wide to support this convergence. The key issue is to know the outcome of the stan- dardswritingprocessbeforeone starts.If thegroup is not clear what needs to be accomplished,
24、they can never be sure when they are finished. Given a clear purpose, the next step is people. The group of standard writers needs to be a diverse lot. Gearmanufacturers,metallurgists,lubricantsuppli- ers, and end users all need a seat at the table. Ev- eryone has a different view of the problem and
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