3 Alice Street, Bassendean 6054

Perth, Western Australia

A.C.N 114 806 969 A.B.N. 39 114 806 969
TELEPHONE: (+61 8) 9279 5522
FAX: (+61 8) 9279 9386

EMAIL: mail@hofmann.net.au
http://www.hofmann.net.au

Hofmann Engineering:

Forged Steel Gearing

Holger Fritz
 3 Alice Street, Bassendean 6054
Perth, Western Australia
A.C.N 114 806 969 A.B.N. 39 114 806 969
TELEPHONE: (+61 8) 9279 5522
FAX: (+61 8) 9279 9386

EMAIL: mail@hofmann.net.au
http://www.hofmann.net.au

ABSTRACT
In response to an increasing number of failures of cast steel girth gears on grinding mills
around the world, Hofmann Engineering has developed technology to fabricate
interchangeable replacement girth gears from high purity steel forgings to quality levels which
meet or exceed AGMA 2001 Grade-2 requirements. Replacement forged steel gears have
been supplied for SAG, Ball and Rod mills from 24’ to 36’ diameter. As the cost of forged steel
gears has now become competitive with cast steel gears, new-build Greenfield projects with
mills up to 40’ diameter have specified forged steel gears for new SAG mills and for their
attendant Ball mills. Over ten fabricated gears are currently in various stages of manufacture.
Mining companies are also purchasing the forged gear rim material as insurance stock, as its
cost is significantly lower than stocking a completed cast gear. This insurance material can
then be fabricated, machined and gear-cut, to suit any number of gear designs, at a later time
as determined by onsite gear inspection and monitoring programs.
 3 Alice Street, Bassendean 6054
Perth, Western Australia
A.C.N 114 806 969 A.B.N. 39 114 806 969
TELEPHONE: (+61 8) 9279 5522
FAX: (+61 8) 9279 9386

EMAIL: mail@hofmann.net.au
http://www.hofmann.net.au

INTRODUCTION
While the event of a failing cast steel girth gear is not a new phenomenon to the mining
industry, it is fortunate that the range of potential solutions has now expanded via the
availability of large diameter forged steel gears. Over the past decade there have been at least
fifty known events of gear failures in areas such as in Chile, Asia, Africa and Australia.
Replacement girth gears have been flown around the world in jumbo jets to expedite deliveries
and grinding mills have stopped or been run at significantly reduced power and production until
the replacement gear could be delivered and installed. Presently several large grinding mills
are known to be operating with cracked or deteriorating cast steel girth gears.

Figure 1: Installation of 8MW SAG Mill Gear in 2010

 3 Alice Street, Bassendean 6054
Perth, Western Australia
A.C.N 114 806 969 A.B.N. 39 114 806 969
TELEPHONE: (+61 8) 9279 5522
FAX: (+61 8) 9279 9386

EMAIL: mail@hofmann.net.au
http://www.hofmann.net.au

BACKGROUND
Since the nineteen-seventies, other non-grinding applications, such as marine gearing and
gears for mining shovels & draglines, had commenced the move from cast steel to forged steel
gear rims for smaller diameter gears up to approximately four metres (13 Ft) diameter. The
primary benefits were improved gear ratings and significantly longer gear life. Hofmann
Engineering, which had been established in 1969, was by the early 1990’s already
manufacturing forged fabricated steel (as well as cast steel and SG/nodular iron) gears up to 8
metres (26 Ft) in diameter. In 1995 work was commenced on an 8-metre diameter, 80-tonne,
fabricated full contour induction hardened SAG mill girth gear for a large bauxite-alumina plant
in Western Australia. This was for a 24’ diameter 3,750 kW 5,000HP SAG mill on which the
original cast steel girth gear was deteriorating due to tooth cracking. The replacement gear
was manufactured in 24 weeks and was installed by Hofmann on-site installation teams during
1996.

Figure 2: Installation of 14.4 MW SAG Mill Gear in 2006

During the past 15 years over a hundred forged steel gears have now been manufactured, and
another ten are currently in various stages of manufacture. The largest forged steel girth gears
produced to date have been;
- 13.2 metres diameter for a 34’ SAG mill in Chile
- 12.4 metres diameter for two 32’ SAG mills in PNG
- 12.2 metres for a 36’ SAG mill in Western Australia
 3 Alice Street, Bassendean 6054
Perth, Western Australia
A.C.N 114 806 969 A.B.N. 39 114 806 969
TELEPHONE: (+61 8) 9279 5522
FAX: (+61 8) 9279 9386

EMAIL: mail@hofmann.net.au
http://www.hofmann.net.au

FORGED STEEL FABRICATED GEAR MATERIALS

The rim material used for forged steel gears has evolved to match and later improve-upon the
physical and metallurgical characteristics of steel gear castings. The American Gear
Manufacturers Association (AGMA) has produced the standard AGMA 2001 which specifies
some 23 requirements for gear rim materials to be classed as Grade 2 gear material. The gear
rim material specially developed for large mill girth gears is labelled Hofalloy-1, which meets or
exceeds all AGMA Grade-2 requirements. Key areas include;
- Forging Reduction Ratio
- Steel Cleanliness and Microstructure
- At least 90% Martensitic composition
- Heat treatment – Quenched & Tempered
- Fine grain size – ASTM 7 or finer
- Yield and tensile strength
- Impact resistance
- Through-section mechanical properties
- Absence of microstructure laminations
- Ultrasonic and Hardness confirmation prior to manufacture

Forgings for rim material are manufactured in specially selected steel mills to Hofmann-defined
specifications. The thickness of plate required relates directly to the diametrical pitch or module
of the gear teeth to be eventually cut in the fabricated gear, for example;
1 DP / 25.4 Module utilises 150 mm (6”) minimum plate thickness
¾ DP / 33.867 Module utilises 205 mm (8¼”) minimum plate thickness.

Figure 3: a) Hofalloy Plate UT inspected at Hofmann; b) Oxy cutting of plate to required lengths; c) Stock Hofalloy

The length of rim material is limited by production and transport parameters, and is between
9.4 metres and 15.5 metres long. Using this length of raw material, new or replacement girth
gears can be designed in 2, 3, 4 or five segments to suit production, transport and installation
limitations.
 3 Alice Street, Bassendean 6054
Perth, Western Australia
A.C.N 114 806 969 A.B.N. 39 114 806 969
TELEPHONE: (+61 8) 9279 5522
FAX: (+61 8) 9279 9386

EMAIL: mail@hofmann.net.au
http://www.hofmann.net.au

DESIGN & AGMA GEAR RATINGS

Mill girth gears were designed in the past to the AGMA 321.05 and since the year 2006 to
AGMA 6114. These standards prescribe calculation methods for service factors (SF) of the
gears:
- Pitting/Durability Resistance Csf, normally 1.75 or greater
- Strength/Breakage Resistance Ksf, normally 2.50 or greater

Figure 4: Hofmann design utilises 3D modelling & can make use of FEA Analysis

Quench and tempered forged steel rim materials have improved mechanical characteristics
over normalised steel castings. Typical comparative data are as follows:

Cast Steel Forged Steel Fabricated

Hardness (typical minimum) HB 285 320
Tensile Strength MPa 880 1,080
Elongation % 8 16
Impact Resistance (0°C) Joules 25 55
Using the improved mechanical properties of forged fabricated gear material allows the
designer to either;
(a) Obtain improved Durability and Strength service factors when using the geometry
of an existing girth gear,
(b) Increase power on an existing mill (subject to motor and drive train issues) while
maintaining adequate service factors, or
(c) Reduce the face width and weight for new gears when designing for kW-
transmitted compared to a cast steel gear.
 3 Alice Street, Bassendean 6054
Perth, Western Australia
A.C.N 114 806 969 A.B.N. 39 114 806 969
TELEPHONE: (+61 8) 9279 5522
FAX: (+61 8) 9279 9386

EMAIL: mail@hofmann.net.au
http://www.hofmann.net.au

A worked example for a 4,100 kW/ 5,500 HP single-pinion drive 28’ ft diameter SAG mill would
be as follows. The base gear data table is;
- Module 29.029 (7/8 DP)
- Helix Angle 7° 15’ 0”
- Face width 850mm (33½”)
- Gear diameter 10.5 metres (34 Ft)

Cast Steel Forged Steel Fabricated

Hardness (Brinell) 285 320
Csf Pitting/Durability SF 1.80 2.25
Ksf Strength/ Breakage SF 2.55 2.80

In the above example, if the forged steel gear was installed on the SAG mill using the same
geometry as the cast steel gear, then the power of the mill could be increased by
approximately 15% from 4,100 kW to 4,700 kW, while still maintaining the stated service
factors of 1.8 and 2.5 respectively.

A Hofmann forged and fabricated gear may also be full contour induction hardened to 45 HRC
which allows for a further increase in power capacity.
 3 Alice Street, Bassendean 6054
Perth, Western Australia
A.C.N 114 806 969 A.B.N. 39 114 806 969
TELEPHONE: (+61 8) 9279 5522
FAX: (+61 8) 9279 9386

EMAIL: mail@hofmann.net.au
http://www.hofmann.net.au

FABRICATION ASPECTS OF FORGED STEEL GIRTH GEARS

Forged rim material arrives from the steel mill as flat forgings up to 43 tonnes in weight, 15 m
long, and 2.5 m wide. After initial test work to validate the steel mill certificates, the rim forging
is pre-heated and cut down to width appropriate to the face-width of the new gear plus
machining allowances.

Figure 5: a) Web, Joint & Gusset plate ready for fabrication; b) 6,000 Tonne Roll Press; c) Bending of Rim plate

The cut plates are preheated and rolled to the appropriate radius for the gear using a unique
6,000- tonne vertical roll press. The prepared web plate is then fitted to the rim plate and tack-
welded into place. There are tight tolerance limits for the root gap between the web and rim
plates at this stage. The web and rim plates are then welded together with a full penetration
weld.
 3 Alice Street, Bassendean 6054
Perth, Western Australia
A.C.N 114 806 969 A.B.N. 39 114 806 969
TELEPHONE: (+61 8) 9279 5522
FAX: (+61 8) 9279 9386

EMAIL: mail@hofmann.net.au
http://www.hofmann.net.au

The gussets are welded in place with fillet welds all around. The joint plates are welded in
place with full penetration welds to both the rim and the web plates.

Figure 6: a) Rim plates post rolling; b) Web to rim welds post UT & MPI inspection; c) Fabrication complete

The full penetration welds are tested ultrasonically and by magnetic particle. The fillet welds
are tested by magnetic particle. The acceptance criteria is normally Australian Standard
1554.1 SP however fabrication may be carried out to other international standards if required.

It is important that the kilo joule input and weld depositions be controlled to minimise distortion
within the structure. Jigs and direct measurement are used to control the manufacturing
process at this stage.

Each gear segment is individually stress relieved after the gear teeth have been gashed in.
 3 Alice Street, Bassendean 6054
Perth, Western Australia
A.C.N 114 806 969 A.B.N. 39 114 806 969
TELEPHONE: (+61 8) 9279 5522
FAX: (+61 8) 9279 9386

EMAIL: mail@hofmann.net.au
http://www.hofmann.net.au

GEAR MANUFACTURING PROCESS

The gear teeth are first rough-cut using a carbide tipped cutter. The removal of rim material in
this process causes some movement and deflection of the gear blank, so it is at this point that
stress relieving is undertaken as noted above.

Accurate setting of the ends of each segment follows, using a horizontal CNC floor borer to
finish machine the split faces and to drill the holes for the fitted bolts and clearance bolts at
each gear joint.

Figure 7: a) Segments ready for machining; b) Segment rough-cut; c) Split lines complete & etch tested

The gear is then assembled on the gear cutter for final gear cutting. The Hofmann Engineering
standard method of gear cutting for large gears is the involute form cutting process. All large
gears are finished to AGMA Quality 10 to 11. Hofmann Engineering has a fleet of nine gear
cutters, of which, three can cut gears of 8 metres diameter up to 15m maximum diameter.

Figure 8: Finish gear cutting

 3 Alice Street, Bassendean 6054
Perth, Western Australia
A.C.N 114 806 969 A.B.N. 39 114 806 969
TELEPHONE: (+61 8) 9279 5522
FAX: (+61 8) 9279 9386

EMAIL: mail@hofmann.net.au
http://www.hofmann.net.au

INSURANCE SPARES
With currently high prices for metallic and industrial mineral products, production interruptions
or delays due to deterioration or failure of a cast steel girth gear have high economic
consequences. In addition, insurance companies offering production interruption insurance
now demand higher levels of inspection and monitoring by mine operators.

For a large mining group operating a fleet of perhaps twenty gear-driven grinding mills, the cost
to purchase a spare cast gear for each mill might be US$10 million in total and the delivery
would exceed one year for the first gears. On the other hand, after a survey of all the mills in
the company’s fleet, it may be possible to recommend a stock of insurance forged plate of
different thickness and lengths that could, subject to need and prioritisation, be cut to size and
fabricated into a range of girth gears for the grinding mills. The period to fabricate and finish cut
the gear from rim plate stocks on-hand would be 16 to 24 weeks.

The cost of such a stock of insurance rim plate may not exceed one-tenth that for spare cast
gears, depending on the range of plate thickness required to suit the tooth-form of the existing
mill girth gears.

Hofmann Engineering already holds insurance stock of forged rim plates for three major
international mining groups under agreements which permit storage of the gear rim material for
five years without charge.

FUTURE PROJECTS
Forged steel gears are now being specified for new grinding mills on some projects in
preference to cast steel or cast nodular iron gears. Recent examples have included Cerro
Corona in Peru for 24’ SAG and 20’ Ball mills; Phu Kham in Laos for 34’ SAG and 24’ Ball mills
and Nullagine gold project in Western Australia. Currently Hofmann Engineering is exporting
grinding mill girth gears, of both cast and fabricated types to Canada, Brazil, Chile, Uruguay,
Peru, Zambia, and DRC Congo - in addition to holding a significant presence in the Australian
market for gears, reducers and onsite installation and service.

Further details on Hofmann Engineering and forged fabricated girth gears can be obtained via
the website www.hofmannengineering.com

12th July 2011