For gears larger than 3 m (10 feet) in diameter, construction of gear blanks tend to be divided into cast steel,
ductile iron, and forged rim welded web structures for use in cylindrical grinding mills and kilns. This paper will
review the application, various options for material selection, and the impact of selection on tooth geometry. A
group of sample gears are developed to compare each of the materials and methods of blank construction.
Each sample is discussed in light of structural stress, deflection, expected life, handling weight, material
origin, fabrication method, inspection requirements during construction, and impact of selection on field
performance. Based on the above, a road map is developed listing critical considerations and optimal use of
each material and method of construction in this application.

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