Simulation And Design Method Research Of Large Gear Lightweight Of Ball Mill

Ball mill was widely used as a powder equipment in many industrial applications, such as building material, metallurgy, mineral processing and power. Its status was irreplaceable. The drive way of ball mill had two kinds, edge transmission and center transmission. In edge transmission ball mill the small gear meshed the large gear which was fixed on the cylinder, and the large gear drove the mill, it could use either high or low speed motor. For the center transmission ball mill, the center lines of reducer output shaft and the mill were collinear. It usually used only high speed motor. The large gear of edge transmission mill was cheaper, so it was applied more widely. Because our mill balls were too heavy, the effective energy utilization rate was very low, and most of the energy was lost as heat energy. Therefore, it is necessary to research the simulation and design method of large gear lightweight.Lightweight technologies included the design of structure optimization technology, new material technology and multidisciplinary integrated optimization design technology. In China, nurtured by ball mill manufacturing market, the product technology and manufacturing capabilities had greatly improved, but there was still a large gap compared with international advanced level.In order to get sustainable development, Chinese ball mill industry must study as soon as possible, create new structure conforming to the need of the society of energy saving and emission reduction. The green design technology including new materials, new technology, can promote resource and energy saving and environmental protection.This paper mainly focused the following aspects of mill gear lightweight research:(1) Ball mill gear lightweight method. According to modern theories developed specific programs and processes of the mill gear lightweight design, selected the appropriate FEM tools according to the process content;(2) Ball mill gear tooth width analysis based on lightweight design. According ball mill and gear transmission mechanism, built the large gear statics contact and bending models, and simulated. Based on characteristics and structural strength analyzed different tooth width models and determined the lightweight gear tooth width;(3) Ball mill gear spoke structural lightweight design. Built the statics model of the large gear spokes, and via gradually topology optimization determined the large gear spoke lightweight structure;(4) Dynamic and modal checking for the ball mill gear lightweight modal. Build lightweight gear dynamics and modal analysis model, simulated explicit dynamics and modal model based on structural strength, dynamic characteristics, engagement stability, efficiency and the whole parameter index, and checked the lightweight gear structure security.On the basis of the modern theory of lightweight design, combined the traditional mechanical calculation, finite element simulation technology and topology optimization, this study put forward the complete and reasonable lightweight design method based on FEM, and solved the actual lightweight design problems based on the above method. After Lightweight design the quality of large gear was decreased by 30.32%, the efficiency of ball mill has been improved effectively.