{"id":2032,"date":"2026-04-10T07:25:30","date_gmt":"2026-04-10T07:25:30","guid":{"rendered":"https:\/\/helicalcutgears.top\/?post_type=product&p=2032"},"modified":"2026-04-10T07:32:17","modified_gmt":"2026-04-10T07:32:17","slug":"mining-machinery-carburized-helical-gear-18crnimo6-forged-din-class-6-for-high-impact-industrial-drives","status":"publish","type":"product","link":"https:\/\/helicalcutgears.top\/ceb\/product\/mining-machinery-carburized-helical-gear-18crnimo6-forged-din-class-6-for-high-impact-industrial-drives\/","title":{"rendered":"Makinarya sa Pagmina nga Carburized Helical Gear \u2014 18CrNiMo6 Forged, DIN Class 6 para sa High-Impact Industrial Drives"},"content":{"rendered":"
\n

Mining Machinery Carburized Helical Gear \u2014 Overview<\/h2>\n

The mining machinery carburized helical gear<\/strong> from Korea Ever-Power Worm Gear Co.,Ltd is a heavy-duty power transmission component manufactured specifically for the demanding shock and abrasion conditions found in underground mining equipment, surface excavators, conveyor gearboxes, and ore-processing machinery. The combination of 18CrNiMo6 nickel-chromium-molybdenum alloy steel, forged blank production, and a full carburizing-and-grinding manufacturing sequence produces a gear with a hard, wear-resistant case over a tough, shock-absorbing core \u2014 exactly the mechanical property profile that mining drives require. Standard spur or through-hardened mga helical gears<\/strong> do not provide this combination: a hard-through gear is brittle under impact, while a soft gear wears rapidly under abrasive dust contamination. Case carburizing solves both problems simultaneously.<\/p>\n

\"Carburized<\/p>\n

The reference gear for this product is a right-hand helical cut gear<\/strong> with module M=9, 33 teeth, an 8\u00b0 helix angle, 20\u00b0 pressure angle, and a profile shift coefficient of x=0.2. This tooth geometry has been selected to balance tooth bending strength with smooth engagement characteristics for the gearbox input speed ranges typical of mining machinery. Korea Ever-Power’s manufacturing capability extends to external gears up to 2,500mm outer diameter and 45mm module for tooth-ground finishes, covering the full size range of mining and metallurgical gearbox applications from compact shearer drives to large mill pinion gears. For customers who need a direct mga helical cut gears<\/a> replacement for an existing worn component, reverse engineering from sample gear or drawing is a standard service.<\/p>\n

Product Specifications and Manufacturing Capabilities<\/h2>\n

Pangunang Datos sa Gear \u2014 Konpigurasyon sa Reperensya<\/p>\n

\n\n\n\n\n\n\n\n\n\n
Parametro<\/th>\nBili<\/th>\n<\/tr>\n
Porma sa Ngipin sa Gear<\/td>\nInvolute<\/td>\n<\/tr>\n
Materyal sa Himan<\/td>\n18CrNiMo6<\/td>\n<\/tr>\n
Proseso sa Himan<\/td>\nForging, carburization, plane and internal grinding, tooth grinding, wire cutting<\/td>\n<\/tr>\n
Anggulo sa Presyon<\/td>\n20\u00b0<\/td>\n<\/tr>\n
Lebel sa Kalidad<\/td>\nDIN 3962 Klase 6<\/td>\n<\/tr>\n
Tipo sa Himan<\/td>\nM=9, Z=33, a=20\u00b0, \u03b2=8\u00b0, x=0.2, Right-Handed<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Mga Kapabilidad sa Paggama \u2014 Mga Internal nga Gear ug Internal nga mga Spline<\/p>\n

\n\n\n\n\n\n\n\n\n\n\n\n
Parametro<\/th>\nPAGGILID<\/th>\nPAGPORMA<\/th>\nPAGGILIT SA NGIPON<\/th>\n<\/tr>\n
Kinatas-ang OD<\/td>\n2500 mm<\/td>\n2500 mm<\/td>\n2500 mm<\/td>\n<\/tr>\n
Minimum nga ID<\/td>\n650 milimetro<\/td>\n50 milimetro<\/td>\n100 milimetro<\/td>\n<\/tr>\n
Pinakataas nga Lapad sa Nawong<\/td>\n500 milimetro<\/td>\n500 milimetro<\/td>\n500 milimetro<\/td>\n<\/tr>\n
Maximum Diametral Pitch<\/td>\nD.P. 1<\/td>\nD.P. 1<\/td>\nDP 0.5<\/td>\n<\/tr>\n
Pinakataas nga Modulo<\/td>\n26 milimetro<\/td>\n26 milimetro<\/td>\n45 milimetro<\/td>\n<\/tr>\n
Lebel sa AGMA \/ DIN<\/td>\nKlase 8 sa DIN<\/td>\nKlase 8 sa DIN<\/td>\nKlase 4 sa DIN<\/td>\n<\/tr>\n
Paghuman sa Ibabaw sa Ngipon<\/td>\nRa 3.2<\/td>\nRa 3.2<\/td>\nRa 0.6<\/td>\n<\/tr>\n
Pinakataas nga Anggulo sa Helix<\/td>\n\u00b122.5\u00b0<\/td>\n\u00b122.5\u00b0<\/td>\n\u00b145\u00b0<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Mga Kapabilidad sa Paggama \u2014 Mga Panggawas nga Gear ug Panggawas nga Spline<\/p>\n

\n\n\n\n\n\n\n\n\n\n\n\n
Parametro<\/th>\nHOBBING<\/th>\nPAGGILID<\/th>\nPAGGILIT SA NGIPON<\/th>\n<\/tr>\n
Kinatas-ang OD<\/td>\n1250 milimetro<\/td>\n2500 mm<\/td>\n2500 mm<\/td>\n<\/tr>\n
Minimum nga OD<\/td>\n20 milimetro<\/td>\n200 milimetro<\/td>\n20 milimetro<\/td>\n<\/tr>\n
Pinakataas nga Lapad sa Nawong<\/td>\n500 milimetro<\/td>\n500 milimetro<\/td>\n1480 milimetro<\/td>\n<\/tr>\n
Maximum Diametral Pitch<\/td>\nD.P. 1<\/td>\nD.P. 1<\/td>\nDP 0.5<\/td>\n<\/tr>\n
Pinakataas nga Modulo<\/td>\n26 milimetro<\/td>\n26 milimetro<\/td>\n45 milimetro<\/td>\n<\/tr>\n
Lebel sa AGMA \/ DIN<\/td>\nKlase 8 sa DIN<\/td>\nKlase 8 sa DIN<\/td>\nKlase 4 sa DIN<\/td>\n<\/tr>\n
Paghuman sa Ibabaw sa Ngipon<\/td>\nRa 3.2<\/td>\nRa 3.2<\/td>\nRa 0.6<\/td>\n<\/tr>\n
Pinakataas nga Anggulo sa Helix<\/td>\n\u00b145\u00b0<\/td>\n\u00b145\u00b0<\/td>\n\u00b145\u00b0<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Carburizing and Heat Treatment \u2014 Why 18CrNiMo6 Matters for Mining Drives<\/h2>\n

\"helical<\/p>\n

18CrNiMo6 is a case-hardening alloy steel with chromium and nickel additions that give it two properties essential for mining gear applications: high core toughness and deep hardenability. The chromium content (1.5\u20131.8%) improves hardenability, ensuring that carburizing produces a consistent hardened case even on large-diameter gear bodies. The nickel content (1.4\u20131.7%) maintains core ductility after quenching, so the gear can absorb the shock loads from ore crusher drives or conveyor overloads without brittle fracture through the tooth root.<\/p>\n

The Carburizing Process in Sequence<\/h3>\n

The complete manufacturing sequence for this carburized helical gear<\/strong> is: forging \u2192 rough machining \u2192 carburizing (gas atmosphere furnace, case depth 1.5\u20132.5mm for module M9) \u2192 quenching \u2192 stress-relief tempering \u2192 plane and internal grinding (to correct heat-treatment distortion on reference surfaces) \u2192 tooth grinding (to DIN class 6 final accuracy, Ra 0.6 tooth flank) \u2192 wire cutting (for keyway, spline, or relief features requiring tight dimensional tolerances after hardening). The tooth grinding after heat treatment is the critical step: it removes the profile error introduced during carburizing distortion and brings the tooth flank to the final accuracy class, ensuring that the gear operates at its designed contact ratio and load distribution from the first hour of service.<\/p>\n

Forging vs Casting \u2014 Why Forged Blanks Are Specified for Mining Gears<\/h3>\n

Forged helical gear<\/strong> blanks have grain flow that follows the contour of the gear cross-section, which aligns the material’s strongest direction with the principal stress direction in the tooth root. Cast blanks, by contrast, have random grain orientation and often contain internal shrinkage porosity or inclusions that act as stress concentration points under cyclic loading. For mining drives that experience regular shock loads \u2014 such as a conveyor belt starting under full load, or a jaw crusher encountering an oversize rock \u2014 a forged blank can absorb significantly more impact energy before crack initiation at the tooth root than a cast blank of identical nominal composition. Korea Ever-Power specifies forged 18CrNiMo6 blanks as standard for all mining and heavy-industry mga helical gears<\/strong> above module M6 and for any gear subjected to impact loading, regardless of module.<\/p>\n

\"mga<\/p>\n

Gear Failure Modes in Mining Environments \u2014 and How Carburizing Addresses Them<\/h2>\n

\"heavy<\/p>\n

Surface Pitting and Spalling<\/h3>\n

Pitting is the progressive formation of small craters on the tooth flank surface under cyclic Hertzian contact stress. It begins at sub-surface crack nucleation sites \u2014 often just below the depth where maximum shear stress occurs under normal contact loading. A high-hardness carburized case (HRC 58\u201362) raises the allowable contact stress limit significantly compared to a through-hardened gear (HRC 48\u201354), pushing the fatigue threshold well above the normal operating stress range. The residual compressive stress introduced by the quench process further suppresses crack propagation, so carburized gears resist pitting initiation for considerably longer service intervals than alternative hardening methods.<\/p>\n

Tooth Root Bending Fatigue<\/h3>\n

The tooth root is the highest-stress location in a gear under load \u2014 bending stress peaks at the root fillet. In mining drives with frequent start-stop cycles and load reversal (such as reversing conveyors), the tooth root experiences fully reversed bending stress, which reduces the allowable stress amplitude to roughly half the one-way bending fatigue limit. The combination of a hard case (which raises the surface fatigue limit) and a tough core (18CrNiMo6 with 1.4% Ni provides good fracture toughness even at lower temperatures) gives the best combination of surface resistance and bulk toughness available from a case-hardening alloy. Shot peening of the root fillet after grinding can further increase the root fatigue limit by introducing beneficial compressive residual stresses \u2014 available on request.<\/p>\n

Abrasive Wear from Contaminated Lubricant<\/h3>\n

In underground mining environments, fine mineral dust inevitably enters the gear housing through seals, particularly on conveyor drives and heading machine gearboxes. Mineral particles harder than the tooth flank surface act as a three-body abrasive between the mating tooth flanks. A carburized case at HRC 58\u201362 is harder than most common rock minerals (quartz has a Vickers hardness of approximately 1100 HV; the carburized case reaches 700\u2013750 HV) \u2014 so the carburized surface resists abrasive wear far better than a hobbed-and-normalized gear at HB 220\u2013280. Combine this with a fine-ground tooth surface (Ra 0.6) that holds a stable oil film more readily than a rough-cut surface, and the result is markedly reduced wear rates in contaminated lubricant conditions.<\/p>\n

Core Performance Advantages<\/h2>\n

\"usa<\/p>\n

 <\/p>\n

\n
\n

\u25c6 High Impact Resistance<\/strong><\/p>\n

18CrNiMo6 with 1.4% nickel content maintains core toughness after quenching. The forged blank’s aligned grain structure absorbs sudden shock loads from crusher overloads and conveyor start-up impulses without initiating cracks at the tooth root.<\/p>\n<\/div>\n

\n

\u25c6 High Surface Hardness HRC 58\u201362<\/strong><\/p>\n

The carburized and quenched case reaches HRC 58\u201362 at the tooth flank surface, raising the allowable Hertzian contact stress limit and resisting both surface pitting and abrasive wear from contaminated lubricant in underground mining environments.<\/p>\n<\/div>\n

\n

\u25c6 DIN Class 6 Accuracy Post-Grinding<\/strong><\/p>\n

Tooth grinding after heat treatment corrects carburizing distortion and achieves DIN 3962 class 6 accuracy with tooth flank Ra 0.6. This accuracy level supports the designed contact ratio from the first hour of operation and reduces dynamic load amplification at operating speeds.<\/p>\n<\/div>\n

\n

\u25c6 Large-Scale Manufacturing Capability<\/strong><\/p>\n

External gears up to 2500mm O.D. and module 45mm (tooth grinding) can be produced in-house. This scale covers the largest mining and metallurgical gearbox pinions without outsourcing critical operations that could affect dimensional consistency.<\/p>\n<\/div>\n

\n

\u25c6 Full Traceability Documentation<\/strong><\/p>\n

Each gear is supplied with a material certificate (mill heat number, chemical analysis, mechanical properties), hardness test records, and a dimensional inspection report. For safety-critical mining applications, this traceability package meets the documentation requirements of major mining OEM qualification programs.<\/p>\n<\/div>\n

\"carburized<\/p>\n<\/div>\n

Industrial Applications for Carburized Helical Gears<\/h2>\n

Underground Mining Machinery<\/h3>\n

Continuous miners, longwall shearer drives, and heading machines transmit hundreds of kilowatts through compact gearboxes operating in environments with coal dust, mineral particles, and limited maintenance access. The carburized hard case on the tooth flanks resists abrasive wear from dust contamination, while the tough 18CrNiMo6 core handles the shock loads from cutting through rock strata. Gearboxes designed to replaceable specification (drop-in pinion and wheel sets) are a standard supply format \u2014 provide the existing gear’s drawing or worn sample for a matched replacement.<\/p>\n

Ore Processing and Mill Drives<\/h3>\n

Ball mill and SAG mill gearboxes use large-module mga helical gears<\/strong> \u2014 module M12 to M45 is common in this sector \u2014 running continuously under high torque with periodic shock from uneven ore feed. The external tooth grinding capability to module 45mm and OD 2500mm covers the full size range of these mill pinions. For the primary drive stage, carburized and ground gears in 18CrNiMo6 match the service life targets set by mill operators who calculate cost per tonne of ore processed as a key maintenance metric.<\/p>\n

\"carburized<\/p>\n

Metallurgical Rolling Mill Gearboxes<\/h3>\n

Steel and aluminum rolling mills subject their gearboxes to large cyclic torque variations as each billet or slab enters and exits the roll gap. The transient torque spike at entry can reach three to five times the mean running torque. Carburized helical gears<\/strong> in 18CrNiMo6 are the standard specification for rolling mill pinion stands and roughing mill gearboxes because the material’s combination of high core toughness and surface hardness handles both the peak entry torque and the prolonged steady-state rolling loads. Find the full range of industrial-grade mga helical cut gears<\/strong> and options at tiggama og helical gear<\/a> Korea Ever-Power.<\/p>\n

Our Service Process \u2014 Before, During, and After Production<\/h2>\n

 <\/p>\n

Pre-Production<\/h3>\n