 Mining/Construction
 Where
can you get high strength, fatigue-resistant
metal parts to meet your most demanding mining and construction
requirements?
Who can you call when you have a breakdown on a
mining shovel, crusher,
dragline, kiln, or off-highway vehicle—and you need
replacement parts immediately?
Just call Scot Forge!
The Benefits of Working with Scot Forge
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Mining and Construction Forged Parts
Forged shapes...
- Track rollers, swivel
rollers, center pintles, single and double hubs,
dolly wheels, thrust rolls
- Disks, sleeves, riding
rings, swing gears, rope sheaves, spacer rings,
bushings, carrier rolls, drive gears, bevel gears,
ring flanges, pinion
racks, locking collars
- Shafts: pinion, shipper
and drive pinion, swivel roll, pulley, crusher roll,
eccentric, gyratory,
mine hoist
- Cable drums, hollows,
pistons, hydraulic cylinders
- Rail segments, bucket
pins, clutch spiders
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Fast Delivery and Breakdown Service
 Because
we know you can’t afford extensive delays in the field,
we deliver parts quickly. And in case of breakdowns, our
scheduling system allows for daily entry of emergency orders
for immediate production response.
Near Net Shapes
Our forging process produces parts close to net shape with
forged-in instead of machined-in steps, tapers, and I.D./O.D.
dimensions.
A Vast Inventory of Materials
Scot Forge maintains an extensive inventory of material
including carbon, alloy, stainless, tool steel, copper,
and mining-specific
grades such as 4330V and 4350Cu.
 Flexible
Sizes and Shapes
Value Added Options from One Source
 Whether
you need your parts “as forged,” rough machined,
heat treated, tested, or any combination of the above, Scot
Forge provides single source responsibility—so you
can prevent the delays and quality problems that arise with
multiple suppliers.
Forging Advantages
Forgings withstand the rigors of mining and construction far
better than castings and fabrications. Forging provides:
Structural Strength
Forgings provide unmatched structural
integrity by consolidating the ingot center. This eliminates
internal voids which can cause field failures. Their superior
strength promotes part reliability and safety, enabling you
to provide higher warranty levels to your customers.
 Directional Grain Flow
Impact Strength and Fatigue Resistance
Proper orientation of grain flow also assures maximum impact
strength and fatigue resistance, lengthening service life.
Case Study: A Mining Shovel “Geared for Strength”
Activity at a mining site ground to a halt when a gear on
a mining shovel failed, rendering the shovel useless. Productivity
plummeted while the cast gear, which rotates the revolving
frame on the top of the shovel car body, was sent back to
the manufacturer for repairs.
When another failure occurred after only a short time back
in the field, the shovel manufacturer was determined to
find the source of the problem and correct it.
The Root of the Problem: Casting
Designers noted that repeated breakage was occurring at
the root of the teeth. Because the gear had been produced
by casting, it lacked the continuous directional alignment
of grain flow which prevents part fatigue and stress crack-ing,
especially at machined areas such as gear teeth.
Forging a Solution
The designers determined that a forged gear would provide
the superior strength needed for this application.
Forging would optimize the gear’s integrity and mechanical
properties by producing a continuous directional grain flow
in the ring profile, which cannot be achieved through casting. And it would
yield improved structural strength, ensuring optimum part performance under
field service conditions.
 Maintaining
the Right Profile
Scot Forge was selected due to their unique ability to offer
contour-shaped large diameter rolled rings, and their overall
expertise in producing products for mining and construction
applications.
The gear was forged into a rolled profiled ring from a
hot press forged blank of 4330 Vanadium steel, a material
recommended for its mechanical and forgeability properties. The ring weighed
17,600 lbs., had an O.D. of 208",
and stood 18" high. Once forged, it was quenched and
tempered and rough machined. When tested, the part achieved
both high impact properties and high hardness throughout
the entire cross section. The shovel manufacturer then machined
in the gear teeth.
The forged gear has met all expectations, providing a significantly
longer service life. It has resulted in a mining shovel that
is truly “geared for strength” and long-term
productivity.
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A copy of Forging Solutions for Machine Shops from Scot
Forge is available
in pdf format. To view pdfs, you will need Acrobat
Reader. Download a free copy if needed. |
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