In heavy-duty rotary equipment—such as massive ball mills, rotary kilns, and SAG mills—the girth gear operates as the primary power transmission component. Subjected to extreme torque, continuous shock loads, and harsh operating environments, the structural integrity and precision of the gear rings directly dictate the uptime of the entire processing line.

As a premier manufacturer trusted by global industry giants like Metso, thyssenkrupp, and CITIC Heavy Industries, Tenfaye specializes in engineering custom girth gears designed for maximum reliability and peak performance under extreme loads.

1. Ultra-Large Scale Customization & High-Precision Manufacturing

Tenfaye's heavy machine shop offers exceptional manufacturing flexibility to fulfill the most demanding structural specifications:

• Dimensional Range: Custom manufacturing capacity spans from φ1,000mm to 16,000mm in diameter, seamlessly covering over 90% of global industrial demand.

• Gearing Specs: Module range covers metric sizes 12mm to 50mm and imperial standards including DP 1, DP 1.25, and DP 1.5. Single casting weight can exceed 1 ton.

• Precision Control: Utilizing Tianshan high-speed gear hobbing and grinding machinery alongside Zhongding advanced machining lines , Tenfaye achieves a precision grade of DIN 6–8 for ground gears and DIN 8–10 for hobbed gears (conforming to ISO 1328-1).

• Surface Topography: The tooth flank surface roughness is strictly controlled at Ra ≤ 1.6μm to 3.2μm. This superior finish reduces friction losses and improves overall transmission efficiency by 4.5%.

2. Premium Metallurgy and Optimised Heat Treatment

To guarantee resistance against fatigue, pitting, and tooth breakage, Tenfaye enforces rigid metallurgical controls:

• Material Options: Fully capable of casting premium alloyed steel grades including ZG35CrMo, ZG42CrMo, ZG45CrMo, ZG35CrNiMo, and ZG34Cr2Ni2Mo.

• Impurity Elimination: Harmful chemical elements like Sulfur (S) and Phosphorus (P) are strictly suppressed to ≤0.025% to maximize structural toughness and minimize casting brittleness.

• Dual Heat Treatment: Through custom-tailored heat treatment profiles—including Annealing, Normalizing, Quenching, Tempering, or full Quenching & Tempering (Q&T) —we achieve a consistent surface hardness of 280 - 320 HB. This specialized dual heat treatment increases overall wear resistance by 52%.

3. 100% Non-Destructive Testing (NDT) & Zero-Defect Philosophy

At Tenfaye, structural reliability is verified through an end-to-end production process, beginning with CAE casting simulation analysis and pit molding. Every single casting is subjected to 100% rigorous NDT protocols in full compliance with ISO, ASTM, DIN, and EN standards:

• Flaw Detection: Comprehensive UT (Ultrasonic), MT (Magnetic Particle), and PT (Penetrant) testing are performed.

• Tolerance Limits: We guarantee zero surface cracks and internal defects restricted to ≤2mm.

• Quality Assurance: With a factory reject rate kept strictly under 0.12% , all shipments are supplied with complete material test reports and NDT sheets. Third-party inspections by SGS and BV are fully supported.

4. Multi-Industry Application Scope

Having successfully delivered over 1,200 customized mill and kiln solutions , Tenfaye’s design optimizations routinely extend equipment service life by 35%. Our heavy-duty girth gears are deployed in 32 countries across diverse sectors:

• Mining & Aggregates: High-tonnage, high-impact SAG mills, AG mills, ball mills, and rotary dryers.

• Cement & Building Materials: Rotary kilns, raw mills, and coal grinding mills.

• Metallurgy & Power: Sintering mixers/granulators, blast furnace driving gears, and wind power yaw/pitch gears.

• Pulp, Paper & Fertilizers: Large debarking drums, sludge dryers, and rotary drum granulators.

Minimize Downtime with Tenfaye: With an optimized manufacturing schedule, Tenfaye offers a rapid 90-day shortest lead time, reducing industrial shutdown waiting losses by more than 60%. All custom girth gears come backed by a 12-month standard maintenance warranty.