IE S012REVITALIZATION CYCLE · JULY 2012 — NOVEMBER 2013
16K20, TV-320, 3B151 machines: higher spindle accuracy, drive draws less power
Spindle runout and play decreased, the drive began drawing less, workpieces came out rounder. 0.02–0.05 mm — spindle radial run-out, 0.04–0.1 → 0.02–0.05 mm; 0.05–0.1 mm — gearbox gear tooth thickness over the constant chord; 7–13 % — drive power under load, 1.05–3.46 → 0.95–3.0 kW; 2–6× — ovality of the control workpiece, 0.006–0.018 → 0.003 mm (2012–2013).
and two technical reports of 2013
What repeated on all five machines
| MACHINE | OPERATING TIME | WHAT WAS MEASURED | REPORT DATE |
|---|---|---|---|
| 16K20 with CNC, inv. No. 10411 | 836 h | Spindle run-out and play, drive power, vibration, gear tooth thickness | 22.11.2012 |
| IZh 1I611PF-1, inv. No. 10366 | 198 h | Spindle run-out and play, drive power, vibration, ovality, gear tooth thickness | 22.11.2012 |
| TV-320, inv. No. 10707 | 154 h | Spindle run-out, drive power, vibration | 22.11.2012 |
| 3B151, inv. No. 16000, shop No. 16 | 512 h | Power and current per phase, vibration at 10 points, workpiece ovality | 11.11.2013 |
| 3B151, inv. No. 16004, shop No. 16 | 495 h | Power and current per phase, vibration at 10 points, workpiece ovality | 11.11.2013 |
Spindle unit geometry — screw-cutting lathes
| MACHINE | PARAMETER | BEFORE | AFTER |
|---|---|---|---|
| 16K20 with CNC, inv. No. 10411 | Radial run-out of the spindle seat | 0.04 mm | 0.02 mm |
| 16K20 with CNC, inv. No. 10411 | Face run-out of the spindle seat | 0.03 mm | 0.02 mm |
| 16K20 with CNC, inv. No. 10411 | Spindle axial play | 0.06 mm | 0.04 mm |
| 16K20 with CNC, inv. No. 10411 | Spindle radial play | 0.03 mm | 0.02 mm |
| TV-320, inv. No. 10707 | Radial run-out of the front spindle bearing | 0.1 mm | 0.05 mm |
| IZh 1I611PF-1, inv. No. 10366 | Face run-out of the spindle seat | 0.01 mm | 0.007 mm |
| IZh 1I611PF-1, inv. No. 10366 | Spindle axial play | 0.04 mm | 0.03 mm |
The gearbox gear tooth thickness on the 16K20 and the IZh 1I611PF-1 grew by 0.05–0.1 mm, and the backlash in the mesh became smaller.
Drive power draw — all five machines
| MACHINE | MEASUREMENT MODE | BEFORE | AFTER |
|---|---|---|---|
| 16K20 with CNC, inv. No. 10411 | Idle running, 1000 rpm | 2.7 kW | 2.3 kW |
| 16K20 with CNC, inv. No. 10411 | Cutting, fixed mode | 3.46 kW | 3.0 kW |
| IZh 1I611PF-1, inv. No. 10366 | Idle running, 2000 rpm | 1.3 kW | 1.05 kW |
| IZh 1I611PF-1, inv. No. 10366 | Cutting, fixed mode | 1.28 kW | 1.18 kW |
| TV-320, inv. No. 10707 | Idle running, 2000 rpm | 0.91 kW | 0.8 kW |
| TV-320, inv. No. 10707 | Cutting, fixed mode | 1.05 kW | 0.95 kW |
| 3B151, inv. No. 16000 | Grinding, 250 rpm, infeed 0.25 mm, per phase | 2.2–2.68 kW | 2.0–2.5 kW |
| 3B151, inv. No. 16004 | Grinding, 250 rpm, infeed 0.25 mm, per phase | 2.3–3.13 kW | 2.12–2.9 kW |
On the 3B151 machines the measurement was taken phase by phase with ATK220 clamp meters; the current under load, according to the report conclusions, dropped by 8.1 and 9.6 %.
Machining accuracy on the control workpiece
| MACHINE | PARAMETER | BEFORE | AFTER |
|---|---|---|---|
| 3B151, inv. No. 16000 | Ovality of the ground workpiece | 0.018 mm | 0.003 mm |
| 3B151, inv. No. 16004 | Ovality of the ground workpiece | 0.014 mm | 0.003 mm |
| IZh 1I611PF-1, inv. No. 10366 | Ovality of the turned workpiece | 0.006 mm | 0.003 mm |
| 16K20 with CNC, inv. No. 10411 | Out-of-flatness of the piston blank face | 0.07 mm | 0.04 mm |
On the lathes the workpiece was turned, on the 3B151 it was ground — the initial ovality levels are of different orders; what is comparable is the direction and the ratio of change.
Vibration of the bed and the spindle headstock
| MACHINE | MEASUREMENT | REDUCTION |
|---|---|---|
| 16K20 with CNC, inv. No. 10411 | Average over the control points of the bed and the spindle headstock | 22.9 % |
| IZh 1I611PF-1, inv. No. 10366 | Average over the control points of the bed and the spindle headstock | 63 % |
| TV-320, inv. No. 10707 | Average over the control points of the bed and the headstock | 39.2 % |
| 3B151, inv. No. 16000 | Vibration velocity at 10 points, 0.384–0.593 → 0.196–0.330 mm/s | 43–56 % |
| 3B151, inv. No. 16004 | Vibration velocity at 10 points, 0.452–0.911 → 0.200–0.628 mm/s | 31–59 % |
On the 3B151 machines vibration was measured with a SENDIG 911 vibration meter at 10 points of the grinding headstock and the bed for three quantities; the table gives the vibration velocity.
Conclusions of the plant commissions
Current equivalent
- Revitalizant gel for gearboxesGearboxes · transmissions · gear drives
- Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
How such units are treated:
About this result:
Limits of this report: The results apply to metal-cutting machine tools of the stated models under the conditions of the machine shops of SE “KhMZ “FED”; on other equipment and in other operating modes the figures may differ.