The companies of Altra Industrial Motion offer many critical drivetrain products utilized in metal processing applications including heavy duty gear drives, brakes and clutches, geared motors and universal joints

1. Applications & Innovations
Metal Processing
Market

2. We’re committed to the
Metal Processing Market
The companies of Altra Industrial Motion offer many critical
drivetrain products utilized in metal processing applications including
heavy duty gear drives, brakes and clutches, geared motors and
universal joints.
Altra Brands Deliver Value Throughout the Drivetrain
Altra Industrial Motion is positioned to provide OEMs with
exceptional drivetrain value by ensuring component compatibility
and optimized performance combined with time-saving,
single-source convenience.
Extensive Technical Experience in Metal Processing
Applications
Major OEMs routinely rely on the vast metal processing application
knowledge of Altra’s engineering teams that collaborate to
thoroughly analyze specific customer applications and then apply
the latest technologies in design, materials and manufacturing.

3. Conversion From Gear Spindles to Ameridrives
ower Transmission Universal Joints Increases
Production and Profits for Cold Strip Mills
Application ProfileApplication Profile

4. • Steel producers have begun to develop thinner, lighter weight auto
gage steels that perform as well and look better than previous
materials.
• Producing thinner alloy steels cost-effectively is challenging as they are
much more sensitive to surface damage from vibrations of rotating
mill rolls.
• Surface-critical exposed prime steel sells for approx. $850/ton. If the
surface is marred or damaged, the steel is downgraded to secondary,
non-exposed usage with a 20% reduction in price (-$170/ton).
• Ameridrives Power Transmission engineers work closely with steel mill
operators around the world to replace their cold mill gear spindles,
which amplify vibration, as they drive the work rolls on the mill stands.
• Mills that have converted from gear spindles to Ameridrives universal
joints have experienced significant increases in production speeds and
yields because of better surface finish due to lower mill vibration.
Conversion From Gear Spindles to Ameridrives
Power Transmission Universal Joints Increases
Production and Profits for Cold Strip Mills
www.AltraCouplings.comP-7762-APT.pdf

5. Application Profile
Cold Strip Steel Mill
Problem:
A major steel producer was experiencing excessive wear and
vibration of the gear spindles on their 5-stand tandem cold mill
with various spindle brands lasting only 6 months. The surface
damage to the steel from the spindle vibration caused the
operator to either slow the mill down, reducing production by
20% to reduce the vibration, or replace the spindles.
Solution:
Ameridrives Power Transmission was approached by the mill
to provide more reliable spindles, however, APT engineers
recommended an even better solution... replacing all the gear
spindles with Americarden Model U3440 universal joints.
• New U-joints allowed the mill to run at record-setting
production levels with reduced vibration and minimal related
surface damage.
Americardan Model U3440 Universal Joints

6. Application Profile
Steel Processing Line
Problem:
A large steel producer needed a new gear drive for a flattener
on one of their processing lines. Direct coupled to a 500 HP
motor, the large gear reducer drives a series of nine de-
tensioning rollers that relieve residual stresses as the strip
steel gets pulled through them during the sizing of the coil.
Solution:
Nuttall engineers custom-designed a drive to meet the
customer’s performance requirements including specific center
distances between shafts and a unique shaft arrangement
configuration.
• Drive featured a 4.5:1 reduction ratio with 650/1200 RPM input
and 140/260 RPM output
• Special circulating oil system developed for the upper gearing
and bearings that are not submerged in oil
Custom Flattener Drive

7. Application Profile
Steel Processing Line
Problem:
A major steel producer needed an upgrade to a straightener
gear drive. The service requirement on the existing drive was
increased which caused the most heavily loaded gear in the
train to fail due to overload. Driven by a 500 HP motor, the
straightener pulls strip steel through two sets of rollers that
relieve stresses while straightening the coil.
Solution:
Nuttall Gear was selected over a competitor to provide the
upgraded gear drive based on their long standing working
relationship with the customer and their reputation for designing
and manufacturing robust steel mill gear drive solutions.
• Rebuilt Nuttall drive featured a reduction ratio of 1:1, a
1.25 service factor with a 160 RPM input and 160 RPM output
• Upgrade included changing from through hardened gears to
carburized and ground gears for enhanced wear resistance
Straightener Drive Upgrade

8. Application Profile
Steel Tube Forming Mill
Problem:
A major steel mill OEM required a custom gear drive for use on
the pinion stand that pulls steel coil through a tube mill which
forms the steel prior to seam welding.
Solution:
The OEM contacted Nuttall Gear based on their previous
successful collaborations. Nuttall engineers designed a custom
drive that was properly sized to meet the performance
requirements while fitting within an extremely tight space
limitation.
• Unique reducer consisted of two independent gear trains, with
15" vertical offset center distance, enclosed in one housing.
• Each train had a reduction ratio of 46:1, a 1.5 service factor
with 1150/2300 RPM input and 25/50 RPM output.
• Through hardened gearing and a fabricated steel housing
Custom Pinion Stand Drive

9. Application Profile
Steel Slitting Line
Problem:
A major steel processor in Detroit was experiencing repetitive
recoiler gear failures on their slitting line. The failures were
occurring at a rate of every three to four months and plagued
the plant with expensive repairs and extended downtimes. A
Nuttall study determined that the unit was underrated and
massive overloading was responsible for the gear failures.
Solution:
Nuttall proposed an upgrade for the existing unit, with a
substantial increase in the service factor that would exceed the
load currently placed on the recoiler.
• Custom-designed gear train delivered
• Gear set installation assistance provided
• Increased unit service factor from .8 to 1.7
• Precision ground carburized gearing exceeds AGMA
Class 13 specification
Recoiler Gear Drive Upgrade

10. Application Profile
Steel Mill Slitting Line
Problem:
A replacement clutch solution was needed at a steel processing
facility that was experiencing slipping in the threading drive on
its slitting line. The clutch, mounted between the low-speed
threading drive and the slitting rollers, automatically disconnects
the drive to protect it from the over-speeding condition when
the slitting machine is run at high production speeds.
Solution:
Formsprag Clutch supplied a grease-lubricated, 10" diameter
FSO-800 clutch with a 13,000 lb.ft. (17,680 Nm) torque capacity
to meet the challenging application requirements. FSO
overrunning clutches feature a high torque density and require
no adjustments or controls. These clutches mount on a through
shaft, with the inner race driven by a key. All models contain
Formchrome®
sprags and Formsprag “Free-action” retainers.
FSO Overrunning Clutches

11. Application Profile
Steel Pickling Line
Problem:
A large steel recoiler OEM needed a custom gearbox and
braking solution for use on a new steel pickling line recoiler. The
drive is direct-coupled to a 125 HP electric motor which winds
up a 52" wide, 60,000 lb. steel coil after it passes through the
pickling treatment line.
Solution:
The OEM contacted Nuttall Gear due to previous successful
drive projects. Nuttall engineers designed a custom gearbox
incorporating a customer-supplied low speed shaft that
operates a mandrel which expands and contracts to grip
and release the coil core.
• Drive features a 15.5:1 reduction ratio of 15.5:1, 1.2 service
factor, 850/2500 RPM input and 55/160 RPM output.
• A Twiflex MX13 spring-applied, pneumatically-released caliper
brake was also utilized for parking and holding functionality.
Recoiler Gearbox and Caliper Brake

12. Coal Mine Conveyor
Problem:
The Australian coal industry is recognized as the most
efficient in the world. To achieve and maintain this position
they invest in modern, high quality technology to ensure
safe and controlled braking of expensive belting.
Solution:
Premier Collie is situated some 200 kilometers south of Perth
Western Australia where two conveyors transport 600 TPH
from an open cast mine to a nearby power station.
• Two Twiflex spring applied, hydraulically released VCS type
calipers acting on a meter diameter disc
• Installed on the tail drive of each conveyor
• Able to bring conveyor system to safe and controlled stop
• Capable of acting as holding brake when conveyor is
stationary
Application Profile
VCS Caliper

13. Application Profile
Annealing Furnace Conveyors
Problem:
GMH, a leading European steel supplier, had originally
envisioned using servo geared motors to drive a new annealing
furnace’s upstream and downstream conveyor systems at their
mill. Bauer pointed out the considerably higher costs of the
servo solution compared to asynchronous motors.
Solution:
Bauer worked with Prämab, the conveyor engineering firm and
German furnace manufacturer, Mioba, to design a new, more
cost-effective layout using Bauer BG Series gear motors. It was
determined that only 30 watts power was necessary compared
to 2.2 kW power maintained by the competition.
BG Series models feature:
• Compact, economical design with high-tensile cast housings
• Operating temperature to 80°C.
BG Series Gear Motors

14. Thin Gauge Steel
Coating Line
Problem:
The challenge at a regional window treatment company was to
achieve consistent tension on a steel web to ensure a uniform
spray application of the final coating in their manufacturing
process.
Solution:
Wichita Clutch application engineers determined that a brake,
applying 500 lbs. of tension across the total web width, needed
to be installed on a set of 24” diameter nip rollers positioned just
ahead of the final coating applicator. Wichita’s ModEvo size
300/4 brake was the ideal choice to provide the necessary
torque and heat dissipation for this unwind application.
• 557 ft.lb. torque capacity and 6.71 thermal HP heat capacity
(with supplied optional fan).
• Unique modular design provides tension control versatility
Application Profile
ModEvo Tension Control Brake

15. Press Pump
Problem:
The grid coupling on a large water pump at Sheffield
Forgemasters Engineering Ltd. (S.F.E.L.) was coming to the end
of its operational life and needed to be replaced to prevent a
breakdown. To avoid costly and time-consuming re-engineering
of the pump, S.F.E.L. wanted to commission a custom coupling
to match the original’s footprint and performance envelope.
Solution:
Unlike other coupling suppliers, Altra Couplings had the facilities
to manufacture a coupling that matched the design of the original
and work in partnership with S.F.E.L. to produce it. Altra
engineers employed modern materials and the latest grid profile
to provide the flexibility and longevity required by the application,
all on a very short lead time.
• Original coupling manufactured by Bibby Turboflex in the 1970s
• Unusually large grid coupling: 1620mm (63.7 in.) outside dia.;
650mm (13.7 in.) width.
Application Profile
Grid Coupling

16. Service Profile
Onsite Bearing Overhaul
Problem:
When a major steel processor in Ohio identified a problem with
the bearings on their slitter line during routine vibration analysis,
they turned to Nuttall Gear.
Solution:
The Nuttall Gear Field Service team immediately put a plan of
action in place to provide two service technicians for a complete
replacement of the bearings on the critical recoiler drive.
• The Nuttall team came in during an off-peak weekend time slot
and accomplished the task in only 16 hours.
• The mill was back up and running first thing Monday morning.
• Nuttall supplied all the tooling and labor necessary to complete
the job, which freed up the customer’s maintenance team for
other critical repairs in the plant during the short two-day
outage.
Steel Slitting Line Recoiler Drive