New Items

FEA Analysis Services

Approx Price: Rs 15,000 / Day/Onwards 
Now a day’s Finite Element Analysis is being used to analyze failure analysis. FEA Analysis Services finds extensive application of FEA is in aerospace, automotive industry as well. In FEA, exact virtual model of machine element has been tested under practical conditions. Depending upon the test results, machine element can modify for its best performance in practice. We use FEA to carry out design review of kiln and components under normal operation. The review and corrections ensures reliable and dependable operation,

Recently we had carried out F.E.A. analysis to establish root cause of cement kiln support roller shaft shearing.

Kiln Tyre Grinding

Approx Price: Rs 15,000 / Day 
Our company is recognized as one of the proficient Service Providers involved in rendering services for Kiln Tyre Grinding. Usually, question being asked for need of grinding of tyres and reasons attributed for change in shape of tyre raceways from square to convex / concave because of followings :

The abnormalities in kiln operating conditions, like :

High shell runout
High tyre wobble
Misalignment in kiln axis
Improper support roller axis, etc

Tyre wobble also called as tyre axial runout or tyre throw and usually consequence of installation error, kiln shell bend thermal or mechanical taper wear on chair pad etc.

Tyre wobble leads to reduced contact between tyre and support roller in part of kiln revolution. The reduced contact result in higher hertz pressure on rollertyre surface and has its own consequence and causes accelerated wear on rolling surface and adversely affects kiln axial balancing as well. From the figure, it is obvious the wear is convex on tyre and concave on support roller. The wear begins series of problems like hot bearings, failure of tyre retainers, accelerated wear of raceways etc. Once wear pattern established, accelerated wear can be expected in order to adjust kiln axial movement by adjustment of the worn out support rollers.

Obvious solution for the above anomaly is to restore square tyre and roller raceways.

Supports rollers are expected to operate about an axis and the resurfacing is relatively easy.

However, the resurfacing for the tyre is not easy because of wobbling in lateral and axial direction. And, tyre was removed from position and bored in vertical boring machines and reinstalled. As the methodology is not economical, an innovative approach is required beyond normal machining methods and tyre grinding machine is developed for the resurfacing.

It comes under into Kiln Tyre .

Kiln Shell Analysis

Approx Price: Rs 15,000 / Day 
Deflection and Bent, we are measuring by standard method of measurement of distance to rotating kiln section. The data analyzed and presents as polar diagram for eccentricity and local deformations. Additionally, we measure roller shaft deflection to conclude hidden cranks of the shell at support roller position. Also, we reverse calculate the shell bent causing shaft deflection and consider this in the real final shell axis shape.

Support Roller Deflection

We carry out support roller deflection measurement, a dynamic deflection during normal kiln operation. Data recorded for complete rotation of kiln using high precision digital dial gauge of accuracy 0.001 mm. The deflection indicate “hidden bend in kiln shell”, support roller shaft strength under operation load, etc.

Kiln shell runout / eccentricity and hidden crank induce cyclical shaft deflection and leads to incipient of fatigue crack in the shaft.

Static deflection of the shaft will be higher but this we can’t measure; we can measure only variation in the deflection during operation. The static deflection can only be measured during shutdown.

It comes under into Kilns .

Kiln Shell Ovality

Approx Price: Rs 15,000 / Day 
• Kiln shell Ovality is an important parameter to assess kiln health and the monitoring become mandatory upon recurring refractory problem.
• Ovality, is defined as difference of shell diameter in horizontal and vertical axis. The difference arises because of flexing in kiln shell during operation, thermal, material loading, etc. attributed for the difference.
• The shell flexing is governed by following factors:
a. Beam strength of tyre
b. Kiln shell thickness
c. Kiln shell and tyre temperatures
d. Kiln shell misalignment
e. Air gap between tyre ID chair pad OD
f. Thermal and material loading
g. High run-out of kiln shell close to support stations, etc.

It comes under into Rotary Kilns.
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