Reconditioning

Australian Kiln & Mill Services offers an 'on line' tyre and trunnion roller surface reconditioning service. That is, worn or damaged running faces of tyres and rollers can be machined flat and parallel while the vessel is in operation.

The Machining Process

• To machine a tyre, the machining rig is set to the vessel inclination and the ceramic tipped cutting tool is set at the horizontal tangent height of the tyre by means of adjustable support legs. Using guide rollers, the cutting head is forced to follow the tyre. This 'floating' arrangement allows achievement of a flat finish regardless of tyre movement. A parallel surface of within 0.5mm on the diameter is generally achievable with this method. Tool feed rate is controlled by a variable speed drive which can be set to obtain the desired surface finish.
  
• To machine trunnion rollers, the machining rig is mounted directly onto the bedplate. Should this not be possible then the machining rig can be mounted onto a temporary structure welded to the bedplate. The machining rig is set parallel to the trunnion roller centreline and the cutting tool is set at the horizontal tangent height of the trunnion roller. The tool feed rate is controlled by a variable speed drive which can be set to achieve the desired surface finish. A parallel surface of within 0.2mm on the diameter can be achieved in this way.
  
• During the machining process the vessel axial thrust characteristics will change. The machining crew monitor vessel reactions and make compensatory adjustments to trunnions to maintain equilibrium of the vessel.
  
• After completion of the machining process the finished diameter of the tyre or trunnion roller is measured using an electronic diameter-measuring device and trunnion roller settings are calculated to compensate for the reduced diameters. The vessel is left in a balanced state of axial thrust, although it is normal procedure for the vessel to require further tuning adjustments as the running faces 'polish-up'. These tuning adjustments are normally carried out 8-10 days after completion of the machining process.
  

Australian Kiln & Mill Services provides a full 'on line' tyre and trunnion roller reconditioning package. Our experienced technicians carry out the service with no input required from the client. Tyre and trunnion roller diameters are measured before and after reconditioning to ensure a flat and taper free result is achieved with removal of a minimum amount of metal. The rotary vessel will be left in a balanced state on completion
of this reconditioning process.