1. Feed machinery equipment accessories big gear product introduction
In the field of feed production, the efficient and stable operation of machinery and equipment is the key to ensure feed quality and yield. The big gear, as one of the core components of many feed machinery transmission systems, undertakes the important mission of transmitting power and changing speed and torque. Its performance is directly related to the reliability, production efficiency and service life of the whole equipment. This product introduction will delve into the structural characteristics, material characteristics, manufacturing process, performance advantages, application scenarios and maintenance points of large gear accessories for feed machinery and equipment, in order to enable readers to have a comprehensive and in-depth understanding of this key accessory.
2. Structural characteristics
Tooth shape
The tooth of the big gear is one of its key features. Common tooth shapes include straight, helical and herringbone teeth. The tooth line of the straight gear is parallel to the axis of the gear, and its design and processing are relatively simple, and it is widely used in some low-speed and light-load feed machinery transmission, such as the mixing shaft transmission of the small feed mixer. However, when the spur gear is running at high speed, because the tooth surface contact is instantaneous, it is easy to produce large impact and vibration, the noise is relatively high, and the bearing capacity is limited. The tooth line of the helical gear is inclined to the axis. In the transmission process, the contact of the tooth surface is gradually entered and separated. This characteristic makes it run more smoothly, the noise is significantly reduced, and the carrying capacity is improved. It is widely used in the main drive of feed granulator with medium speed and medium load. The helical gear combines the advantages of straight teeth and helical teeth. The helical structure of the double side teeth effectively balances the axial force and has a strong carrying capacity. It is often used in large and heavy duty feed crushing equipment or the key transmission parts of continuous production line, but the manufacturing process of the helical gear is complex and the cost is high.
Wheel hub and rim design
The hub is the part of the wheel that connects the large gear to the shaft, usually with a keyway or spline to achieve a precise fit with the shaft and transfer torque. The size and shape of the wheel hub should be designed according to the diameter of the connected shaft, the torque size and the assembly requirements, etc., to ensure the firmness and reliability of the connection. The rim is the part that carries the teeth of the gear, and its thickness and width directly affect the strength and bearing capacity of the gear. For large gears that bear large loads, the rim is often designed to be thick and wide to enhance the support strength of the teeth and prevent the teeth from deforming or breaking during long-term use. In addition, a reasonable transition fillet design is usually adopted between the rim and the hub to reduce stress concentration and improve the overall fatigue life of the gear.
Overall size and accuracy requirements
The diameter of the big gear depends on the transmission needs of the specific feed machinery, which can range from tens of centimeters to several meters. Its dimensional accuracy, shape accuracy and tooth surface roughness have a crucial impact on the transmission performance of the gear. The high-precision large gear can ensure good meshing with the matching gear, reduce transmission errors, reduce noise and vibration, and improve transmission efficiency. For example, in high-precision feed ingredients measuring equipment, the pitch deviation of the big gear needs to be controlled within a very small range to ensure the accuracy and stability of the ingredients.
3. Material characteristics
High quality alloy steel
Many large gears of feed machinery and equipment are made of high quality alloy steel, such as 40Cr, 42CrMo, etc. These alloy steels have good comprehensive mechanical properties, high strength, good toughness and certain wear resistance. After the quenching and tempering treatment, the hardness of 40Cr alloy steel can reach HRC28-32, which can meet the strength requirements of the general feed machinery transmission, and is often used in the manufacture of large gears in small and medium-sized feed processing equipment. 42CrMo alloy steel contains molybdenum element, further improve the hardenability and strength of the material, after tempering and surface quenching treatment, the surface hardness can reach HRC50-55, in large, heavy duty feed machinery, such as the main transmission gear of large feed pellet press excellent performance, can withstand high torque and greater impact load, Effectively prolong the service life of the gear.
Carburizing steel
For some cases where the hardness and wear resistance of the tooth surface are very high, carburized steel such as 20CrMnTi is widely used. Carburized steel through carburizing quenching treatment, can form a high hardness of carburizing layer on the tooth surface, hardness is usually up to HRC58-62, while the heart still maintains a relatively low hardness and good toughness, this "surface hard toughness" characteristics make it in the high surface contact stress and impact load performance excellence. In the high-speed transmission gear of the feed crusher, the carburized steel big gear can effectively resist the tooth surface wear, fatigue spalling and other failure forms, to ensure the long-term stable operation of the equipment, reduce maintenance costs and downtime.
Stainless steel
In the feed production environment, if there are wet, corrosive media or high requirements for health conditions, stainless steel gear becomes the first choice. For example, 304 stainless steel has good corrosion resistance and oxidation resistance, which can resist the erosion of water, acid and alkali components and microorganisms in the feed to ensure the normal operation and service life of the gear. In aquatic feed processing equipment or food grade feed production equipment, stainless steel gear can effectively prevent gear performance degradation and pollution caused by corrosion, and ensure the quality and safety of feed products.
4. Manufacturing process
Forged blank
The blank of the big gear is usually prepared by forging process. The forging process can refine the grain of the metal material and make the organization more dense, so as to improve the strength and toughness of the material, and eliminate the internal defects caused by the metal in the smelting process. The blank after forging needs to be normalized or annealed to eliminate the forging stress, improve the cutting performance of the material, and lay a good foundation for the subsequent machining process.
machining
Machining links include turning, milling, gear hobbing, gear shaper and other processes. First, the outer circle, end face and wheel hub parts of the forged blank are processed to the design size through turning processing, and the features such as keyway are processed. For the machining of tooth shape, the hobbing process is one of the most commonly used methods, which uses the principle of developing motion between the hobbing cutter and the workpiece to gradually cut out the gear teeth. Gear hobbing can ensure high gear profile accuracy and production efficiency, and is suitable for machining cylindrical gears of various modules and teeth. Gear shaper process is often used for machining internal gear, double gear or some gears with special tooth shape requirements, it through the up and down reciprocating motion of the gear shaper cutter and the rotating motion of the workpiece to complete the tooth shape processing. In the machining process, it is necessary to strictly control the processing accuracy of each process, and adopt high-precision machine tools and tools to ensure that the dimensional accuracy, shape accuracy and tooth surface roughness of the big gear meet the design requirements.
Heat treatment
Heat treatment is a key step to improve the performance of large gears. For large gear made of alloy steel, tempering treatment is generally adopted, that is, quenching and tempering at high temperature after quenching, so that the gear can obtain good comprehensive mechanical properties and improve the matching degree of strength and toughness. For large gears made of carburized steel, carburizing, quenching and low temperature tempering are required. Carburizing treatment makes the tooth surface rich in high concentration of carbon elements, forming a high hardness carburizing layer after quenching, low temperature tempering further eliminates the quenching stress, stabilizes the structure and size, and improves the wear resistance and fatigue strength of the tooth surface. In the heat treatment process, it is very important to accurately control the heating temperature, holding time, cooling speed and other process parameters, otherwise it will easily lead to defects such as gear deformation, cracking or uneven hardness.
Surface treatment
In order to further improve the surface performance of the big gear, the surface treatment can be carried out according to the actual demand. For example, nitriding treatment can form a nitriding layer with high hardness, good wear resistance and certain corrosion resistance on the gear surface, which effectively improves the anti-bite ability and wear resistance of the tooth surface. At the same time, the nitriding treatment temperature is low, and the influence on the deformation of the gear is small. Hard chrome plating treatment can significantly improve the hardness and finish of the tooth surface, reduce the friction coefficient, reduce the tooth surface wear and power loss, suitable for some feed machinery gear with high surface quality and transmission efficiency requirements.
5. Performance advantage
High precision drive
With precision manufacturing and strict quality control, the large gear has excellent dimensional accuracy and tooth profile accuracy, and can achieve precise meshing with the matching gear. This high-precision transmission characteristic can effectively reduce the pitch error and tooth profile error in the transmission process, so as to reduce vibration and noise, and improve the stability and reliability of the feed machinery transmission system. In the metering device transmission of feed ingredients system, high-precision big gear can ensure the precise proportion of ingredients, avoid the feed formula deviation caused by transmission error, and ensure the consistency of feed product quality.
High carrying capacity
With high-quality material selection, reasonable structural design and advanced manufacturing process, the large gear has a strong load capacity. Whether it is the impact of high torque at the start of the moment, or under the continuous load during stable operation, the big gear can reliably transfer power, and is not prone to fatigue wear of the tooth surface, root fracture or plastic deformation. In the mixing shaft drive system of a large feed mixer, the big gear needs to bear huge mixing resistance and dynamic load, and its high bearing capacity ensures that the mixer can run stably for a long time, improving production efficiency and equipment utilization.
Good wear resistance and durability
Through the use of appropriate materials (such as carburizing steel, alloy steel, etc.) and combined with effective heat treatment processes (such as carburizing quenching, tempering, etc.), the tooth surface of the big gear has a high hardness and wear resistance, which can effectively resist the tooth surface wear, fatigue pitting, gluing and other common failure forms during long-term and high-intensity operation. At the same time, good material toughness and structural design also ensure the durability of the gear under impact load. In the feed granulation production line, the wear resistance and durability of the big gear are directly related to the continuous running time and maintenance cycle of the production line, and high-quality big gear can significantly reduce the maintenance cost and downtime of the equipment, and improve the production efficiency.
Strong fit
Large gears can be customized according to the specific transmission needs of different feed machinery and equipment. Whether it is the module of the gear, the number of teeth, the shape of the teeth, or the size of the hub, the form of the keyway and other parameters, it can be flexibly adjusted to achieve a perfect match with various motors, reducer and other transmission components. This high degree of adaptability makes the large gear can be widely used in all kinds of feed machinery, such as shredders, mixers, granulators, extruder, conveying equipment, etc., to build a diverse and efficient and reliable transmission system to meet the requirements of different feed production processes and equipment layout.
6. Application Scenarios
Big gear is widely used in feed machinery and equipment. In the feed crusher, the big gear as the core transmission component, the motor's high-speed rotating power is transferred to the grinding tool, so that it can operate at the appropriate speed and torque, to achieve the efficient crushing of various feed raw materials. In the feed mixer, the big gear drives the mixing blade to rotate to ensure that different types and different proportions of feed raw materials are fully mixed in the mixer to achieve the expected mixing effect. For feed pelletizing machine, the big gear is responsible for extruding the tempered powder feed between the ring die and the press roller, and its stable transmission performance plays a key role in ensuring the quality and yield of pellet feed. In the feed expander, the big gear provides power for the rotation of the screw, so that the material is rapidly expanded under high temperature and high pressure environment to form an expanded feed product. In addition, in feed conveying equipment, such as chain conveyors, bucket elevators, etc., big gears are also involved in the transmission system to drive the smooth operation of the conveyor chain or conveyor belt to achieve the smooth transfer of feed materials between different production links.
7. FAQ
Q: What is the main material of the big gear?
A: Large gears are usually made of high-strength steel or alloy steel to ensure that they have sufficient strength and wear resistance. These materials can withstand high loads and long periods of use.
Q: How to choose the right big gear size?
A: Choosing the right large gear size needs to consider the power, speed and load of the equipment and other factors. Ensure that the selected size can meet the design requirements and conditions of use of the equipment.
Q: What are the surface treatment processes for large gears?
A: Common surface treatment processes for large gears include quenching, carburizing and nitriding. These processes can improve the hardness and wear resistance of the surface and extend the service life.
Q: How to ensure the transmission efficiency of the big gear?
A: In order to ensure the transmission efficiency of the big gear, the meshing accuracy between the gear and other meshing parts should be ensured, the lubrication system should be checked and maintained regularly, and the lubricating oil should be kept clean and appropriate.
Q: What problems may occur in the use of large gear?
A: The big gear may have problems such as wear, fracture, deformation or poor meshing during use. These problems are usually caused by overload, inadequate lubrication, or material defects.
Q: What are the special requirements for large gears in different application scenarios?
A: In different application scenarios, large gears may have different special requirements. For example, large gears used in high temperature environments need to have high temperature resistance; For use in corrosive environments, corrosion-resistant materials are required.
