Ball Mill Gear Simulation and Reinforcement, Sarcheshmeh Copper Complex

In this paper, simulation and reinforcement of the ball mill gear in Sarcheshmeh Copper Complex were analyzed. The purposes were a prediction of crack growth, simulation of stress distribution, a model of deformation and suitable reinforcement. Finite element method was used in this analysis. First, according to a real model which is used in the production cycle, detailed information about the boundary conditions was collected. The gear model was simulated entirely by using computer software. The gear is modeled based on a damaged gear, and the damaged gear is off the production cycle. The carried out results of the analyses were compared with the real gear. Different models were applied to reinforce the gear and the model presented is the most appropriate one, in order to optimize the stress distribution and deformation of the gear. The selection factor for choosing the reinforcements are maximum stress, deformation and applicable. Stress and deformation of gear have been declined 39.5% and 21% respectively by applying the reinforcements. The paper results are used on one damaged gear.