SPICER GELENKWELLENBAU. Fully Forged Heavy Duty Shaft with a rotation diameter 950 mm by Böhler Bleche GmbH/Austria

Transcription

1 SPICER GELENKWELLENBAU Fully Forged Heavy Duty Shaft with a rotation diameter 950 mm by Böhler Bleche GmbH/Austria R

2 SPICER GELENKWELLENBAU Successful commissioning by Böhler Bleche GmbH At the end of September 2001 Böhler Bleche GmbH in Mürzzuschlag, Austria, a subsidiary company of Böhler Uddeholm AG 1, introduced its new trio-rolling mill for high alloy steel plates and nickel basic alloy. Spicer Gelenkwellenbau Essen (GWB) supplies the main components for the drive including the cardan shafts, connection flanges and Safeset safety coupling. circular saws, stainless specials and nickel basic alloys for special applications. Because of increased requirements it became necessary to replace the old installation that had been operating for the last 50 years with a more modern trio-rolling mill. The design and its structural realisation was done by Voest Alpine Industrieanlagenbau, Linz, Austria. Fig. 1: Old stand before redesigning TRIO-STAND At the end of 2000 GWB received the order to supply the driving elements for the trio-rolling mill of Böhler Bleche. This stand is the core facility of production at Böhler Bleche and makes sure that all operations are provided with the necessary equipment. They manufacture press sheets for technical and decorative laminates, high alloy cold work steel for tools, high speed steel for Some old units were integrated into the new milling line. The main drive train consists of the following parts: 2 identical driving motors (old) with 1,150kW each 1 middle-symmetrically designed reduction gear (old) with 2 flywheels located on both pinion shafts each

3 R 1 pinion coupling with Safeset SR-PF870- safety coupling 1 pinion reducing gear (new) 2 cardan shafts type each with connection flanges (new) to drive top and lower work roll. The intermediate roll is not driven. The old stand consists of 2 slipper type spindles for driving the rolls. They fitted the existing gearbox (Demag) with new case hardened pinions to be able to transmit higher torques. Fig. 2: Layout of the new trio rolling mill Steel cast housing: 76 t Roll force: max. 4,000 t Body length: 2,250 mm Body Ø: Max. roll gap: Top / Lower roll 1,040 / 950 mm Intermediate roll 870 / 770 mm 280 / 20 mm The amount of supply from GWB comprise the following components: Heavy cardan shaft Rotation Ø: 950 mm Flange connection Ø: 950 mm with hirth serration over all Length: 2,850 mm Max. deflection angle: 10 Weight: 11,000 kg Functional limit torque: 7,400 knm Reversing fatigue torque: 3,500 knm Connection flange (gear side) Outer Ø: Weight: Connection flange (roll side) Flat roll end with 2 sliding plates and 2 centring rings for changing unit 1,070 mm 4,000 kg Safeset safety coupling SR-PF870 (fig. 4) Outer Ø: Weight: 1,100 mm 3,850 kg Cylindrical slip joint Outer Ø: Weight: Cut out torque: 1,425 mm 5,870 kg 2,150-4,300 knm

4 SPICER GELENKWELLENBAU The choice of material had us take special steel which, in its quenched and tempered condition, has a maximum tensile strength of 1,200N/mm 2. This high heat treatable steel shows higher fatigue strength of up to 30% when compared to cast steel. Flange yoke and bearing cap were designed by means of the latest FEM-calculations. When proving fatigue resistance we refer to FKM-guidelines 2 that have now become a standard in mechanical engineering. However it takes elaborate measuring on site to be able to calculate any deviation between calculated tension and real actually occurring tension (fig.6). Fig. 3: The new rolling train Planning and manufacturing of each plant parts was done in a record time of 1 1 /2 years. The pure building and assembly time was only 8 weeks. With many honourable guests present the new facility was commissioned at the end of September Fig. 5: Flange yoke after machining and before heat treatment Fig. 4: The new safety coupling For the pulsating load we established a measured load collective of 4,850kNm maximum torque for the cardan shaft. Contrary to common practice with quarto stands the triostand can transmit 80-90% of the entire torque with one shaft. Fig. 6: Measurement of local stretching at a universal joint in operation Based on upon the extremely requirement torque, at a needed deflection angle of almost 10 and a 950mm rotation diameter, the yokes were made as fully forged parts (fig.5).

5 R HEAVY DUTY SHAFT 498 The 498 series has been specially designed for tough conditions like you may find in particular in steel mills. The most innovative features you will find in the design and heat treatment of the drop forged journal cross. The shape, featuring geometrically soft transitions in notch sensitive areas, will undergo inductive hardening, so that we get a hard surface in the designated area in order to guarantee low stress gradients inductance hardening and case depth of up to 25mm is required. This requirement can only be fulfilled when using inductive hardening on the surface hardening. GWB can look back on decades of experience of inductive hardening. Be applying modern methods of calculation (FEM) we were able to optimise the potential for larger torque capacity in the GWB patented journal cross 3. Depending on the deflection angle (5, 10 and 15 ) 4 the diameter of the journal cross can be adapted. The similarly forged bearing cups are hardened to the specification of the bearing manufacturers and come in notch less design. When reducing the diameter of the stud of the journal cross the created space can be used for larger bearing rolls. This results in an adjustment of the lifetime of bearings and torque respectively, tailor-made to customer specification. The high axial forces resulting from centrifugal acceleration of up to 50g are nicely absorbed by axial bearings made of low friction compound material. The sealing of the bearing is effected by a sealing ring which guarantees a high degree of seal-off due to its complex labyrinth. Since due in part to the application of aggressive emulsions, the conditions in the rolling mill operations are quite demanding on the material, grease nipples are made of stainless steel and the yoke additionally sealed with O-rings. The hirth serrated standard flange is sealed by GWB patented high grade steel rings. Max. torque capacity Max. bearing capacity Grease nipple 2. Axial bearing 3. Bearing cup 4. Journal cross 5. Bearing rolls 6. Bolts of bearing cap 7. Bearing cap / Flange yoke 8. Sealing Fig. 7: Cross section of the yoke from 498 series

6 SPICER GELENKWELLENBAU SERVICE There is an ever increasing demand for service friendly design of the heavy duty shaft type 498. We at GWB benefit from our 50 year experience in applying and manufacturing prop shafts of the split bearing eye design type. Fig. 9: Bearing support in flange yokes with closed bearing eye The journal cross can also be dismantle by loosening the bolts on the bearing lid. This enables a complete journal cross assembly exchange in a single day; the shaft can thus go back into operation within a very short period. Fig. 8: Rolls print from bearing rolls on journal cross (compare closed and split bearing eye) 5 While in the sectors of vehicle and secondary drives you will find more shafts featuring closed bearing eyes, we are seeing in the market for heavy duty shafts an increase of the split bearing eye design. Apart from technological advantages such as the increased life time of bearings, load distribution and torque capacity, the service time in the case of exchanging bearings is comparatively low when compared with other designs (for instance flange yokes with closed bearing eye). Fig. 10: Bearing support in flange yokes with split bearing eye Because of the limited number of tools required the easy of repair. Inspections can be accomplished worldwide, on location within a few hours of customers as well.

7 R SUMMARY With the experience gained from this project we have laid the foundation for the next generation of cardan shaft series. Running this project we at GWB have been able to further optimise the system split bearing eye and we are now in a position to guarantee higher transmission capacity and life time. By continually developing heavy duty shaft type 498 as a fully forged variant featuring optimised bearing and at the same time keeping the patented inductive hardening journal cross, we provide rolling mills with the means to transfer the highest possible torques and life time of bearings. In order to sustain our already achieved high level of service friendliness with our product on location you will find an even more improved design featuring split bearing eye. Fig. 11: On-location maintenance on a heavy cardan shaft 498 suburb at a customer plant Fig. 12: Detaching of the bearing caps after loosen the bolts Reference 1 Company paper Böhler FKM-Richtlinie Nr. 154: Rechnerischer Festigkeitsnachweis für Maschinenbauteile 3 Patent-Nr. journal cross GWB: DE C1 4 Industrial catalog GWB 5 GWB tests and calculations: comparison closed ans split bearing eye Heribert Bürvenich, Industrial Distribution Andreas Wons, Industrial Design and Development

8 R SPICER GELENKWELLENBAU Home Country GKN Service International GmbH Service-Center Hamburg D Hamburg Ottensener Str. 150 Tel Fax gkn-ind.hamburg@amo.add.gknplc.com Foreign Country Australia Hardy Spicer Division of Unidrive Pty. Ltd McNaughton Road Clayton, Victoria 3168 Tel Fax russell.plowman@hardyspicer.com.au Austria GKN Service Austria GmbH Slamastrasse 32 Postfach 53 A-1232 Wien Tel Fax gkn.austria@mail.gkngsa.co.at Internet: Also responsible for: Czech Republic, Slowakia, Slovenia, Croatia, Ukraine, Rumania, Bulgaria, Yugoslavia Belgium N.V. Glaenzer Seurre S.A. Av. Paul Gilsonlaan 441 B-1620 Drogenbos Tel Fax glsindustrie@amo.add.gknplc.com Brazil Dana Industrial Ltda. Av. Fukuichi Nakata, 451/539 - Piraporinha - Diadema Sao Paulo Tel Fax fabricio.santos@dana.com China, P. R.C. Wuxi Driveshafts & Machinery, Co. 88 W. Renmin Road, Hudai, Wuxi Jiangsu Province, China Tel Fax office@bcwxz.com Internet: Denmark Dansk Uni-Cardan A/S Baltorpbakken 10 DK-2750 Ballerup Tel Fax info@uni-cardan.dk Internet: Finland Oy Unilink AB Lapinrinne 1 FIN Helsinki-Helsingfors Tel Fax unilink@unilink.fi France GKN Glenco 170, rue Léonard de Vinci F Carrières sous Poissy Tel Fax jean-marie.schutz@fr.amo.add.gknplc.com Great Britain GKN Driveline Ltd. Higher Wood Croft, Leek GB-Staffordshire ST13 5QF Tel Fax r.clews@gkndriveline.co.uk Greece Sokrates Mechanics GmbH 9, Victoria Square GR Athen P. O. Box 3020 GR Athen Tel Fax sokrates@enternet.gr Internet: Hellas Cardan GmbH P. O. Box 40105, Stawrupolis GR Thessaloniki Tel./Fax Hungary Szücs Co. Kárdantech KFT Ipari kepriselelek Aradi Vertanuk ut. 16 H-9022 Györ Tel Fax szucsco@alarmix.ne India XLO India Ltd. 78-B, Dr. Annie Besant Road Worli, Mumbai Tel Fax exloin@vsnl.com Israel Frank Agencies P. O. Box 22307, 10 Pinkas Str Tel Aviv Tel Fax frank-ag@frank.co.il Italy Uni-Cardan Italia S.p.A. Via G. Ferraris 125 I Ospiate di Bollate (MI) Tel Fax info@unicardanitalia.it Japan Nakamura Jico Co. Ltd , Tsukiji, 3-chome Chuo-Ku, Tokyo Tel Fax Netherlands GKN Service Benelux B.V. Haarlemmer Straatweg NL-1165 MK Halfweg Tel Fax industrie@uni-cardan.nl Norway UNI-CARDAN NORGE A.S. Postboks 66, Grefsen N-0409 Oslo Tel Fax rk@gkn-unicardan.no Spain Gelenk Industrial S.A. Balmes, 152 E Barcelona Tel Fax javier.montoya@gelenkindustrial.com South Africa Driveline Technologies CNR. Derrick & Newton Roads Spartan, Kempton Park P. O. Box 2649 Kempton Park 1620 Tel Fax dlt@elcbis.co.za Sweden Svenska Uni-Cardan AB Stensätravägen 9 Box 3100 S Skärholmen Tel Fax info@unicardan.se Internet: Switzerland Schaffner Behrend GmbH Althardstrasse 141 CH-8105 Regensdorf Tel Fax schaffner-behrend@amo.gknplc.com USA, Canada Spicer GWB North America Merovan Business Center 1200 Woodruff Road Suite A-5 Greenville S.C Tel Fax dudley.potter@dana.com Spicer Gelenkwellenbau GmbH & Co. KG, industrial@gwb-essen.de, Internet: P. O. Box D Essen, 2. Schnieringstr. 49 D Essen, Telefon: 0049 (0)201 /