INDUSTRIAL CASE|MECHANICAL ENGINEERING|METAL-CUTTING MACHINE TOOLS
REVITALIZATION CYCLE · JULY 2012 — NOVEMBER 2013
series of 3 acts
16K20, TV-320, 3B151 machines: higher spindle accuracy, drive draws less power
PRODUCTXADO revitalizant compoundstreatment without disassembly of the units, the machines stayed in shop production
TEST OBJECTMetal-cutting machine tools, 5 unitsscrew-cutting lathes 16K20 with CNC, IZh 1I611PF-1, TV-320 · cylindrical grinders 3B151, inv. No. 16000 and No. 16004
DOCUMENT TYPESummary report of 2012
and two technical reports of 2013
and two technical reports of 2013
What repeated on all five machines
↓0.02-0.05mm
spindle radial run-out, 0.04-0.1 → 0.02-0.05 mm
↑0.05-0.1mm
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
| 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
The reports of SE “KhMZ “FED” record: on the 16K20 “all spindle accuracy parameters of the machine improved by at least 33% (the spindle radial run-out decreased 2×) and came into conformity with the data sheet values”, on the TV-320 “the radial play of the front spindle bearing decreased 2× and conforms to the permissible data sheet values”. For the 3B151 the conclusion is the same: “the reduced ovality of the control workpiece and the lower vibration parameters of the machine indicate a reduction of the radial clearances of the bearings due to the formation of a metal-ceramic layer”. Treatment of the gearbox increased the gear tooth thickness by 0.05-0.1 mm, reducing the backlash in the mesh. The IZh 1I611PF-1 machine ran only finishing operations and was within its data sheet limits from the start — it changed less than the others: the coating builds up where there is wear. After a year of regular operation the plant confirmed in a separate report that the achieved parameters had held.
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. The originals of the 2012 summary report and the 2013 technical reports, with signatures and seal, are published in full and available for download.
Current equivalent
- Revitalizant gel for gearboxesGearboxes · transmissions · gear drives
- Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
How such units are treated: