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Laserhärten für TAKRAF: Zahnräder für den Einsatz im Tagebau

Laser hardening for TAKRAF: Gears for use in open-cast mining

Surface hardening of the tooth flanks of 16 gear segments for TAKRAF – one of the leading suppliers of mining technology. The finished gears have a diameter of 9 meters and consist of eight segments, which will later be used in bucket wheel excavators in opencast lignite mining near Neyveli (India).

The task:

Each segment weighs 950 kg, is almost 4 meters long and has 38 teeth. The material: 42CrMo4. The goal: an extremely hard and wear-resistant surface on the tooth flank and tooth base with a tough component core.

The solution:

Laser hardening using scan optics. This surface hardening allows an entire tooth flank to be hardened in just one track without creating a tempering effect – precisely, reproducibly and with minimal distortion. The result is hardness values of up to 55 HRC with a hardening depth of around 1 mm.

The advantages of laser hardening:

Laser hardening with scan optics of tooth flanks
Laser hardening with scan optics of tooth flanks
Laser hardening of the entire tooth flank with just one track
Laser hardening of the entire tooth flank with just one track
Laser hardening of tooth flanks without tempering effect
Laser hardening of tooth flanks without tempering effect
Gear segments: 950 kg in weight and 4 m long
Gear segments: 950 kg in weight and 4 m long
Easy system control through the use of macros
Easy system control through the use of macros
Achieved hardness of 55 HRC and hardening depth of 1 mm
Achieved hardness of 55 HRC and hardening depth of 1 mm

Conclusion:

The laser-hardened segments are assembled into a ring gear and then installed in bucket wheel excavators. They are a key component for the reliable rotation of the uppercarriage during operations under extreme conditions – and an example of how modern laser technology from Dresden makes international mining more efficient and economical.

We have created a video about wear protection for gear rim segments using laser hardening and published it on YouTube:

Would you like to find out more about wear protection using laser hardening? We look forward to providing you with comprehensive advice.