Gearing — Advancing Quality
Rexnord’s Falk™ is the world’s leading manufacturer of ring gears, designs quality in from the start. Our commitment to consistently employ state-of-the-art techniques for design, materials and manufacturing processes enables us to continually enhance performance, reliability and overall lifetime value for customers around the world.
Rexnord® is the only gear manufacturer in the world to offer the total package—from the gear casting, in-house heat treating and carburizing, to sophisticated gear cutting and precision grinding—all under one roof. Plus, Rexnord’s comprehensive product line and project management expertise allow us to engineer complete power transmission and conveying solutions, which help minimize total cost of ownership.
That is why our ring gears are chosen for use in a variety of installations. These include large diameter, kiln, ball mill, SAG mill and high power applications. Industries include mining, cement, sugar, power and paper.
A variety of gear types are available. From straight-cut spur gears to helical configurations, we can produce it. We can even provide double helical gears, or herringbone gears, to overcome the problem of axial thrust presented by "single" helical gears. We utilize finite element analysis to eliminate costly trial and error. New design concepts are thoroughly analyzed for structural integrity prior to production. In addition, our proprietary gear blank “casting” technology contributes to quality and therefore predictability and reliability.
We can produce gears in a variety of material types including cast steel, ductile iron, or fabricated metals such as rolled plate and forged ring. Our extensive experience with steel, both cast and fabricated, and Spheroidal Graphite Iron (SGI) helps you get the best material value for your gear application and performance requirements.
Case Carburizing Increases Surface Hardness, and will significantly improve durability ratings, while extending component life. Our in-house case carburizing facility – 1.7 m diameter x 5.5 m deep (5.6 ft x 18 ft) – coupled with ladle-treated, vacuum-degassed forged steels allow you to uprate power densities, significantly increasing the life of your new or replacement components. Whether it’s a genuine component, manufactured by us, or not, all parts receive the same thorough technical review and are processed to exacting engineering specifications.
MAAG Gear Cutting Capabilities up to 14 Meters (43.5 ft) assure that gear teeth are precisely machined to exacting AGMA tolerances and surface finishes which extend the life of gearing and ensure equipment availability.
An Unmatched Collection of Inspection Equipment — including dimensional, metallurgical, physical, non-destructive and gear tooth inspection — ensures that every component meets the world’s most exacting quality criteria... our own. Below, a fixed centers contact check confirms proper contact on the tooth flanks of both the girth gear and pinion, assuring optimal system performance.