The International Maintenance Seminar 2007 mIDTH INSTITUTE Tyre and Roller Surfaces and How to Repair them By Juan-B. Dominguez Lecture 04-04-06Tyre and Roller Surfaces and how to repair them 14-08-2007 04-04-06 Juan B. Dominguez Lecture Questionnaire 1. Were the subjects of the lecture? 1 important O mostly useful Ci some points useful [1 of no use 2. Was the level of instruction? 0 too advanced O adequate O wo low 3. Was the presentation of the lecture? CO very motivating 0 interesting O moderate O aun 4. How would you rate the lecture overall? C1 very good O gooa O adequate 0 poor 5. Do you feel that all relevant topics were covered in the lecture? O yes Ono If no, please specify: 6. Should some topics be left out in the future? O yes O no If yes, please specify: 7. Did you read the lecture text prior to attending the lecture? O yes O no 8. Ona scale from 1 to 10, how do you rate the lecture as a whole? 1 - poor |2 3 4 5 6 i 8 9 10 - good. Please add any additional changes, suggestions or comments:MmioTH The International Maintenance Seminar INSTITUTE FLSmidth 2007 all rights reserved 67 IMS Lecture: No.04-04-06miptH INSTITUTE The International Maintenance Seminar Table of contents 6. ‘TYRE AND ROLLER SURFACE. 6.1 Visual inspection of tyre- and roller surfaces... 6.2 Damages to the contact surfaces of tyres and roller TB 6.3. Resurfacing of tyres, support rollers and guide rollers. eee Lecture No. 04-04-06 69 ‘FLSmidth all rights reserved.The International Maintenance Seminar fism DTH INSTITUT support rollers are arrying capacity and fatigue strength the materials, dimensions and desi chosen under due consideration thereof n of tyres and 6.2 Damages to the contact surfaces of tyres and rollers If the extend of the contact between tyre and support roller for whatever reason becomes so small that the correspondit the exposed areas. g contact pressure exceeds the material strength wear appears in Figure 6-3 Convex wear on tyre and concave wear on support roller F roller 6-4 Tapered wear on tyre and support The above two macro patterns of the wear are typical: Convex tyre in combination with concave worn support roller and taper worn tyre and support roller worm Potentially, both of these have serious consequences for the availability of the kiln, Both of them put restrictions on the axial mobility of the kiln, because together with the axial movement between tyre and support roller they involves lifting of the kiln (for tapered wear in one direction only), In the extreme wear situation shown on Figure 6-5. Extreme concave wear on support roller figure 6.5 the convex/concave wear has been allowed to continue until a veritable the support roller JKiln to grove has been made leaving no possibility for the ty = [ican SO? ae pee Yaoeruedl:mipTH INSTITUT The International Maintenance Seminar Exposed to concentrated load the highest stress in the tyre and support roller according to theory is the shear stress parallel to and a little below the contact surface. In case this stress exceeds the fatigue limit crack formation is initiated which in time results in loosening of smaller or bigger lumps of material from the exposed surface as shown on figures 6.8 and 6.9. Figure 6-8 Pitting on support roller Figure 6-9. Pitting on tyre Hereby the load c initiating has be; rying surface area becomes reduced and the dangerous spiral of self n: A dangerous spiral which can be stopped only through resurfacing, 6.3 Resurfacing of tyres, support rollers and guide rollers Figure 6-10 Resurfacing lathe mounted for resurfacing of a tyre ——__—___—_—_____— + —- a SNA a Gini Paced,The International Maintenance Seminar Gismioms INSTITUTE Figure 6.14 depicts the method used by diameter measurements. A circular disc of _ known er which shares its shaft diame with an electronic encoder is brought into perpendicular contact with the surface to be measured. The encoder is connected to a likewise electronic counter. The counter starts and stops counting when the beam from a photodiode becomes interrupted by a pointer which is conveniently positioned on the surface to be measured. Figure 6-14 Measuring the diameter ae = ET ET a |= __ Suriaees and how to repair them Surluses ie an fs Meweldedumuy we ‘tuo most probate Maumee voasune SENG J SUDO | perros orubaia EXGESSINEROUER)uisuny <)> Tunusiat One Dit isalile TW neails Mga? anol) jorsa W Toye Ge Winnie wupeavareuNE We hesUu: (a Beevers —os hes eae = = RESULIG Both with the ‘oa CONSEQUENCE that the axial mobility of the kiln on the roliers es reduced | en = a a) =e ‘Tyve wu iulbar te kin moves Baia ql tive Len analy beatally Juesail abut bearing as unauuldile CNIS NENIE) | eerererrar eerVist balers Tsailumens a] GO Gp Sep oy a tyre-unl oa comaere ‘aro lta cows an grou br Sunawas = yr lar Surana ‘Surtasas ‘yze- cum Bose Surlawas =e. ‘ure wun aul ‘sulawseine ‘Tyre- aul Boer ‘Surusae Te idinanwyss thy == Tuustai he sae Gna ltieileaL ‘Deails Misia atal rsa wove te with wy taper ‘tore- au wala ‘curhanas Thrust Rollers a oe, ‘Tuo-a aoe ‘Surtasas Ts balers Atooment |oe of Unie COnCIW ONESGismiorm The International Maintenance Seminar INSTITUTE By resurfaci uses a specially developed lathe design shown on figure 6.10. of tyres F.L.Smidth A/S This special design allows the tyre to be floatingly suspended during machining of tyres. This is necessary in order to comply with the important demand to the quality of the resurfacing that the axis of rotation of the tyre’s contact surface after machi original axis of rotation. The compliance with this demand, which is effectuated through a convenient guiding am ing is identical to the tyre’s ement, is vei impeded by wobbling of the tyre. The present design, however, fully ensures the compliance, During resurfacing of support rollers and guide rollers where the axis of rotation remains identical to the component's original axis of rotation is the lathe mounted in fixed suspension, i.e. without use of the above: mentioned guidi rangement Measurements of the existing or macro wear pattern of the support rollers to be resurfaced constitute an important preparatory activity. Tables like that shown on figure 6.11 can be used here cometry ‘The figures 6,12 and 6.13 show details of the tool holder It appears from figure 6.12 that the tool holder can needed to machine the conical contact surfaces on be adjusted to and advanced in any ang] ide roller and mating tyre. Figure 6-12 Tool holder FLSmidth 2007 all rights reserved. 74 Lecture No. 04-04-06.Fismom The International M INSTITUTE tenance Seminar move axially. This wear pattern is disastrous because it creates enormous axial forces during the heating and cooling phases where the kiln expands or contracts. Complete mechanical failure if the thrust bearings are typical result of this situation. Also the micro pattern of the wear shows different appearances. The mirror-like appearance of the worn areas on figure 6.5 is typical for the grinding wear that becomes the result if clinker dust or raw meal is allowed to enter into the contact between tyre and support roller. In general steel-to-steel wear appears lustreless and grey like on figure 6.6. The micro wear pattern, however, also depends upon what may be called the specific wear mechanism The wear on figure 6.6 is the early result of contact between a tapered tyre and a likewise tapered support roller. Only at one position along the axial line of contact between tyre and support roller does the two components have exactly the same velocity. Away from this position the two contacting components rotate with somewhat different surface velocities. The surface velocity of the tyre is higher than that of the support roller at the one side of this, neutral, position while at the other side the situation is the opposite This situation gives rise to the so-called fish scale wear process (Fig. 6.7) which is a self-increasing process where thin scales of tyre- and roller material are constantly worn off. This process can be stopped only through resurfacing and subsequent adjustment of the contact surfaces. wear is another typical wear phenomenon often met where the contact load for whatever reason has become 100 high e.g. tyre wobbling, excessive roller skewing or inclination and misalignment. igure 6-7. Fish scale wear FLSmidth 2007 all rights reserved. 72 Lecture No. 04-04-06.GBismiorn The International Maintenance Seminar INSTITUTE 6. TYRE AND ROLLER SURFACE 6.1 Visual inspection of tyre- and roller surfaces Among the many important activities belong the visual inspection of the kiln is inspection of the quality of the contacts between tyres and support rollers, When looking at the contact zones from between the support rollers (Fig. 6.1) areas of 10 contact are disclosed as axially slits where light is allowed to penetrate (Fig. 6. Clearly, the wider the slit the poorer is the contact Consequently, bigger load has to be carried by the remaining area of contact resulting in material load and increased wear here. Two situations are common in this respect during one revolution of the kiln Either it is observed that the axial position of the slit of no contact varies harmonically between the inlet side and the outlet side, or, that it remains in Figure 6-1 the same position. The first-mentioned situation is, typically, the result of wobbling of the tyre, while the second, typically, is the result of excessive inclination or skewing of the support roller, ic. non-parallelism between the axis’ of tyre and support roller. By experience variations in the pyrotech processes inside the kiln during operation are unavoidable. Small changes in extend and thickness distribution of the coating is a typical example of the consequences of these variations. Figure 6-2 ; Coating changes, however, mean changes in the heat transmission conditions between charge and kiln shell. Consequently, the temperature distribution on the kiln shell constantly undergoes changes corresponding to the changes in the pyrotechnically processes inside the kiln which, necessarily, cause changes in the kiln shell geometry Unavoidably, such chan; or Variations in the contacts between tyres and support rollers. Consistent with this fact they are in a sense considered “normal” conditions and, therefore, included in the design rules. In re sin the kiln shell geometry are reflected in cha ct of load dit Ciieniiilite aia sad cued aiamatiand, 70 Lecture No. 04-04-06.