Falk Gear Sets Product Sheet
Falk Gear Sets
Rexnord Falk Mill Products
For more than 100 years,
Rexnord Falk Mill Products
have provided high-quality
solutions for a diversified
range of industries. With a
base of over 5,000 installed
ring gears and pinions, the
finest heavy-sectioned, large
steel castings, and some of the
largest machining capabilities,
Rexnord Falk Mill Products
are your solution for some
of the worlds most rugged
applications.
Industries:
Mining
Cement
Automotive
Construction
Manufacturing
Paper
Falk Gear Sets engineered for demanding
applications.
Designed for demanding applications around
the world, Rexnord Falk Gear Sets offer a
precise solution for your application. Gear
sets are designed per exact American Gear
Manufacturers Association (AGMA) standards
to maximize power density while minimizing
size and weight. Replacement gear sets can be
analyzed for more rating and increased power
density by increasing hardness of the gear,
pinion, or both.
Falk Gears Sets are differentiated by:
Total process control the complete
process from engineering, design, pattern
construction, steel casting production, final
heat treatment, to all machining operations,
including finish gear cutting on a 46-foot
(14 meters) MAAG, is under one roof. Every
step of the process is controlled by Rexnord
to exacting standards.
Engineering expertise our engineers are
experts in applying the design requirements
outlined in the AGMA standards. More than
5,000 installed and operating ring gears are
not only a testament to their expertise, but
also to their experience.
Design criteria we utilize premium cast
steel blanks and proven steel alloys that
facilitate homogenous material and uniform
hardness throughout the gear structure.
Our ring gears are designed using delta or
tee cross sections to allow for optimization
of power capacity, minimum weight, and
maximum equipment availability. We also
have the ability to design and produce gears
utilizing ductile iron or fabricated blanks.
Capacity scheduling Rexnords total
process control, combined with real-time
capacity scheduling, enables on-time
deliveries and complete transparency
when communicating order status to our
customers.
Global, reliable service our experts
are available to discuss applications and
provide installation assistance no matter
where you are. Additionally, Rexnord offers
Falk GearPro Training, a customized,
comprehensive ring gear and pinion
maintenance seminar, at customer sites
around the world.
 Falk Gear Sets Capabilities

As an ISO 9001:2008-certified facility with 1 million square feet (93,000

square meters) under one roof, Rexnords Falk Gear Group is dedicated to
accommodating all of your open gear needs, including:

On-site pattern shop provides ability to quickly modify Fully equipped materials lab
patterns to suit prototypes and design changes On-site machine shop handles products up to 250,000 pounds
Fully developed Falk Steel Alloys as well as customer- (113,000 kilograms). It also accommodates large machining
requested materials needs up to:
MAGMASOFT solidification simulation software used to 50-foot (15.2 meters) vertical turning center
predict solidification and ensure casting integrity 46-foot (14 meters) MAAG, one of only three in the world
Molding 12-inch (305 millimeters) horizontal boring bar
Flasks up to 15 feet (4.6 meters) diameter Complete inspections
Pits up to 36 x 80 x 7.5 feet (11 x 24.4 x 2.3 meters) Dimensional checks
Controlled heat treatment Dye penetrant
Deep pit carburizers Dry and wet magnetic particle inspection
Through hardening capabilities Nondestructive and destructive testing
Computer-controlled furnace: 30 x 40 x 15 feet (9.1 x 12.2 x Ultrasonic inspection
4.6 meters) Laser scanning
Portable coordinate measurement capabilities

Rexnord Your Global Partner for Falk Gear Sets

Toronto, Ontario, Canada

(service center)

Milwaukee, WI, USA

(manufacturing facility and service center)
New Orleans, LA, USA
Salt Lake City, UT, USA (manufacturing facility and service center)
(service center)
Newcastle, NSW, Australia
Hermosillo, Sonora, Mexico (manufacturing facility and service center)
(manufacturing facility and service center)

Santiago, Santiago, Chile

(service center)

Examples of Large Falk Gear Sets Around the World

Ghana: 17,420 horsepower (hp) (12,990 kW) ball mill, dual Chile: 15,000 hp (11,185 kW) SAG mill, dual pinion, 532.44-inch
pinion, 408.33-inch (10,372 mm) outside diameter (OD) (13,524 mm) OD
Australia: 20,920 hp (15,600 kW) ball mill, dual pinion, Russia: 9,387 hp (7,000 kW) SAG mill, single pinion,
413.38-inch (10,500 mm) OD 496.62-inch (12,614 mm) OD
Brazil: 21,456 hp (16,000 kW) ball mill, dual pinion, 413.38-inch South Africa: 17,420 hp (12,990 kW) ball mill, dual pinion,
(10,500 mm) OD 408.33-inch (10,372 mm) OD
Canada: 20,116 hp (15,000 kW) ball mill, dual pinion, United States: 24,138 hp (18,000 kW) SAG mill, dual pinion,
508.78-inch (12,925 mm) OD 521.99-inch (13,260 mm) OD

866-REXNORD/866-739-6673 (Within the US) 414-643-2366 (Outside the US) www.rexnord.com

2013 Rexnord GR5-021 Printed in USA 05/13