Description

  1. Tenfaye has rich experience and unique advantages in the production of large girth gears. It has a short casting cycle, high product quality, and can be produced in large quantities. It is currently the product with the largest delivery volume.          2. Unique heat treatment technology is used in the casting process to optimize the structure of the girth gear, improve the hardness, and greatly enhance the wear resistance and impact resistance of the product.          3. The company uses high-strength steel for girth gear casting and optimizes the operation characteristics of the rotary kiln to ensure the stability of the components under long-term operation and extend the service life of the product.
 

Advantages

1. Digital Simulation & Risk Pre-control (CAE Analysis)
Numerical Simulation: We utilize CAE simulation software and Finite Element Analysis (FEA) to model filling and solidification, pre-identifying potential shrinkage risks in "V-shaped" thermal stress zones.
 Precision Feeding Design: Based on thermal field analysis, we deploy multi-stage insulating risers and chilling arrays to guide directional solidification, ensuring a dense internal structure free of defects.
 2. High-Purity Melting & Advanced Molding
Refined Molten Steel: Utilizing the EAF (Electric Arc Furnace) + LF (Ladle Refining Furnace) duplex process, we achieve deep deoxidation and desulfurization, strictly controlling gas content to ensure high material toughness.
 Composite Sand Molding: For the core gear teeth area, we use sodium silicate sand combined with chromite sand. Its superior thermal conductivity enhances surface hardness and finish (Ra ≤ 12.5μm) while preventing sand inclusion.
 3. Scientific Pouring & Controlled Cooling
Step-Gating System: A multi-gate stepped pouring system is used to stabilize the molten steel flow rate and prevent sand erosion.
 Controlled Cooling Program: We strictly execute a long-term slow-cooling curve, allowing the casting to cool uniformly within the mold to suppress thermal cracks at the source.
 4. Stress Relief Heat Treatment
Normalizing + Tempering Cycles: Utilizing fully computerized temperature control, we execute customized heat treatment protocols to eliminate over 90% of internal casting stresses.
 5. Precision Mechanical Processing
Heavy-Duty Rough Machining: Removing the casting skin to reveal the gear profile, followed by the initial Non-Destructive Testing (NDT).
 Secondary Aging Treatment: We implement aging treatment after rough machining to release cutting stresses, ensuring a residual stress elimination rate of over 95% to prevent future deformation. 
6. Stringent Quality Assurance (QA/QC)
100% NDT Inspection: Every unit undergoes mandatory Ultrasonic Testing (UT) and Magnetic Particle Testing (MT) before shipment to ensure zero internal porosity and no surface micro-cracks.