DavyMarkham’s applications' expertise in the field includes mill equipment, heavy presses, turbines, mining equipment, heavy gears and drives, tunnel boring machines, mechanical handling, and many other complex equipment types – supplied and installed worldwide.
The Gear Manufacturing operation enjoys an international reputation, with customers in North and South America, Africa, the Pacific Rim, Europe and throughout the UK.
This unique facility has the capacity for: -
Yet whilst mainly associated with super-large sizes, the company can also cut gears down to 200mm diameter and 40 module.
DavyMarkham has a fully dedicated gear cutting and grinding facility and manufactures:-
The facility is equipped with modern CNC machinery, including two of the largest MAAG and Liebherr models in the country, works to all recognised international standards,
The operation can handle: -
A particular speciality is fabricating composite gear wheels from high quality EN24 steel on lower grade, lightened hubs, in order to reduce cost and weight on very large diameters. Independently certified to ISO9001 and EN29002.
The gear manufacturing facility employs a total quality management system throughout the production process, from design to testing and checking.
Gear and transmission designs are generated using the latest computer-aided techniques
These techniques encompass: -
In-house resources include: -
DavyMarkham applies aircraft-style precision standards to gear engineering and its ability to work to extreme tolerances is particularly exemplified when cutting double helical drives.
Double helical drives These gears feature a circular herringbone pattern, with the right and left helixes converging around the centre spine. Normally, a narrow gap enables cutting or grinding without running into the opposing helix, although considerable skill and precision is nevertheless required.
However, a set of steel mill pinions recently produced for Rodator in Spain were too complex to allow this, so DavyMarkham machined the gears in two separate halves, employing a special expanding mandrel for one half, then shrinking this onto a shaft with the mating half, requiring an extremely high degree of accuracy for such comparatively large components.
The gear manufactring facility has the capacity to design and produce complete transmission units – this is best illustrated by a massive 183 tonne overhead edger gearbox for a rolling mill, which was delivered to CST in Brazil, at a cost of £1 million, and included a gear case that was fabricated in-house, as it was simply too large for casting.
Yet a giant 10m-diameter gear wheel, part of a major engineering contract was too big even for the DavyMarkham’s massive MAAG 480 grinding machine, one of only three in the world. Instead the gear was machined in four separate segments, using conventional machinery, then the quadrants were mated together with the highest degree of precision
– proving that engineering and innovation can go hand in hand.
Our specialist gear cutting and grinding facilities enable us to produce gears up to 3.2 metres in diameter and 1.4 metre face width. Our grinding capacity is up to 4.75 metre diameter and 50 tonne, with a face width of 1.1 metres
