Custom Helical Gear Replacement for Rubber Internal Mixer Gearboxes

Overview:

In the tire manufacturing industry, equipment uptime is critical. We recently completed a precision engineering project for a well-known tire company in Qingdao, involving the replacement of worn-out components in their rubber internal mixer gearboxes. By delivering 5 units of high-performance helical gears, we helped our client restore their production line to peak efficiency and prevent costly unplanned downtime.

Technical Specifications:

• Application: Internal Mixer Gearbox (Tire Production Line)

• Gear Type: Helical Gear (Optimized for smooth transmission and high load capacity)

• Module: M14 (Large module for heavy-duty rubber compounding)

• Material: 20CrMnTi (High-strength alloy steel for maximum durability)

• Quantity: 5 Units (Precision-matched replacement set)

• Process: Precision Gear Hobbing

• Heat Treatment: Quenching & Tempering (Ensuring excellent core toughness and overall structural stability)

• Tooth Surface Treatment: Carburizing & Precision Gear Grinding (Achieving deep case hardness for maximum wear resistance)

• Accuracy Class: DIN 7 (High industrial standard for reliable power transmission)

The Solution – Precision Retrofitting:

• Seamless Integration: These gears were custom-manufactured to match the exact specifications of the original equipment, ensuring a perfect fit and seamless integration into the existing internal mixer gearbox.

• Enhanced Service Life: By upgrading to 20CrMnTi with advanced carburizing, grinding and quenching & tempering processes, the new gears offer significantly higher wear resistance compared to standard replacements, effectively extending the maintenance cycle.

• Precision Engineering: Reaching DIN 7 accuracy through master-class grinding, we reduced the mechanical noise and vibration often found in older machinery, improving the overall stability of the extrusion/mixing process.

Conclusion:

This project demonstrates our expertise in providing high-quality replacement and retrofitting solutions for the tire industry. Our ability to manufacture large-module (M14) precision gears allowed our client to successfully modernize their old equipment with minimal disruption to their operations.