Lathe-group machine tools
The procedure describes the treatment of serviceable assemblies of lathe-group machine tools — spindle units, speed and feed gearboxes, lead screws, guideways and hydraulic systems — with XADO revitalizant gels, without disassembly and without oil change. The purpose of the treatment is the restoration and protection of friction surfaces under normal operating conditions of the machine tool.
12. Procedure for treating lathe-group machine tools with XADO revitalizant compounds
What is treated
- Serviceable assemblies and mechanisms of lathe-group machine tools that have no completely worn or damaged parts.
- Spindle units.
- Speed gearboxes.
- Feed gearboxes.
- Lead screws of machine tools.
- Guideways of machine tools.
- Hydraulic systems.
- Spindle unit and speed gearbox having a common lubrication system (item 12.1).
- Mechanisms of speed gearboxes and feed gearboxes with an autonomous lubrication system (item 12.2).
- Spindle units with an autonomous oil lubrication system (item 12.3).
- Lead screws lubricated with oil (item 12.4).
- Guideways with a centralized circulating oil lubrication system (item 12.5.1).
- Guideways with periodic manual oil lubrication from a separate container (item 12.5.2).
- New spindle units or those with wear of up to 10% — treatment by the same procedure in 2 stages.
- New hydraulic machines or those with initial wear (up to 10%) — treatment by the same procedure in 4 stages.
- New machine tools or machine tools with insignificant guideway wear (up to 10%) — preventive treatment of the guideways.
When treatment is not performed
- Assemblies and mechanisms having completely worn or damaged parts are not subject to treatment.
- Guideways having wear in the form of "saddle-shaped" deformation, protrusions, as well as other damage to the working surface deeper than 0.1 mm are not treated; such defects are first eliminated by machining (planing, grinding), and only then is treatment with the XADO revitalizant compound carried out.
- Treatment is not started until oil leaks have been eliminated (item 12.1.1).
- Treatment of the hydraulic system is not started until working fluid leaks have been eliminated (item 12.6.1).
Preparation
- Eliminate oil leaks before starting the treatment of the spindle unit and the speed gearbox (item 12.1.1).
- Eliminate working fluid leaks before starting the treatment of the hydraulic system (item 12.6.1).
- Take measurements of the principal operating parameters and geometric dimensions of the parts of each assembly before the start of the treatment (the same measurements are repeated after completion of the full cycle).
- By visual inspection of all friction surfaces of the guideways, determine their technical condition (presence of pits, chips, scoring), the degree of wear and the advisability of treatment by the XADO technology.
- In a separate vessel, take a small amount of the standard oil at the rate of 1 part of the gel being added to 5-10 parts of oil, heated to a temperature of 40 - 60°C, add the calculated amount of gel and mix thoroughly until a homogeneous mixture is obtained.
- The prepared mixture is to be added with the machine tool switched off.
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Axial and radial run-out of the spindle mounting surfaces | Indicator stand with a measuring dial indicator, graduation not coarser than 0.01 mm | Measurements are taken by rotating the unloaded shaft with the indicator stylus placed on its radial and (or) end surface and reading the indicator. Before the start and after completion of the full treatment cycle (items 12.1.2, 12.3.1) |
| Radial and axial play (clearance) of the spindle bearings | Stand with a measuring dial indicator, graduation not coarser than 0.01 mm | By forced displacement of the spindle in the radial or axial direction toward the indicator stylus placed on the mounting (radial or end) surface of the spindle, and reading the indicator (items 12.1.2, 12.3.1) |
| Vibration level of the bearing assemblies (vibration acceleration, vibration velocity, vibration displacement) | Vibrometers of various types | In idle running mode with the spindle unloaded, at fixed points of the bearing assembly housing in the vertical, horizontal and axial directions of each bearing support (items 12.1.2, 12.3.1) |
| Vibration level of the speed gearbox or feed gearbox (vibration acceleration, vibration velocity, vibration displacement) | Vibrometers of various types | In idle running mode with the machine tool spindle unloaded, at fixed points of the speed gearbox or feed gearbox housing in the vertical, horizontal and axial directions of the bearing support (item 12.2.1) |
| Power consumption or current consumption of the electric motor | Clamp meter, wattmeter or multi-purpose instrument for measuring electrical circuit parameters | In idle running mode and at fixed cutting modes (at a fixed load), at the same oil temperature (items 12.1.2, 12.3.1); for speed and feed gearboxes — in idle running mode at the same oil temperature (item 12.2.1) |
| Surface roughness of a workpiece turned (machined) with one and the same tool at the same cutting modes | Profilometer of any type; profilometer or profilograph of any type (item 12.3.1) | Before the start and after completion of the full treatment cycle (items 12.1.2, 12.3.1) |
| Taper and ovality of a control workpiece produced (machined) with one and the same tool at the same cutting modes | Micrometer or lever-type snap gauge with a measuring dial indicator, graduation not coarser than 0.01 mm | Before the start and after completion of the full treatment cycle (items 12.1.2, 12.3.1) |
| Thickness of the selected and marked teeth of the speed gearbox gears and gear drives | Gear tooth calipers of any type with a graduation not coarser than 0.05 mm | Take measurements of the gear tooth thickness (see appendix 3); items 12.1.2, 12.2.1 |
| Technical condition of the contact patterns of the marked gear teeth | Visually or by means of a camera | The presence and size of damage are recorded (items 12.1.2, 12.2.1) |
| Noise level | Sound level meters of any type | At a fixed distance from the noise source, in the absence of extraneous noise sources and at fixed operating modes of the machine tool (items 12.1.2, 12.2.1) |
| Axial play in the "screw-nut" pair | — | Measurements before the start of the treatment and after completion of the full treatment cycle of the lead screw (item 12.4.1) |
| Flatness and straightness of the machine tool guideways | Special control straightedges or prisms | Before the treatment and after completion of the full cycle; with a circulating lubrication system — as necessary (items 12.5.1.2, 12.5.2.2) |
| Pressure in the hydraulic system | Calibrated pressure gauge | At a fixed working fluid temperature (item 12.6.2.1) |
| Operating temperature of the oil (hydraulic fluid) in the hydraulic system | Liquid-in-glass thermometer, infrared pyrometer or other standard temperature measuring instrument | Before the start and after completion of the full treatment cycle (item 12.6.2.2) |
| Output (delivery) of the hydraulic pumps | Flow meters | At a fixed pressure and working fluid temperature (item 12.6.2.3) |
| Volume of working fluid internal leakage during hydraulic motor operation over a fixed period of time | Measuring vessel (container) with a graduated scale | At a fixed pressure and constant working fluid temperature at the hydraulic motor outlet (item 12.6.2.4) |
| Vibration level of the hydraulic machine | Vibrometer | At specified points at fixed operating modes of the hydraulic system (item 12.6.2.5) |
| Output of the hydraulic pumps of power hydraulic systems (indirectly) | Measurement of the time of fixed travel of the power hydraulic cylinders | Determined by the actuation speed of the power mechanism at constant pressure and operating oil temperature (item 12.6.2.6) |
| Hydraulic tightness of the directional control valves (indirectly) | Comparison of the amount of displacement of a loaded serviceable power hydraulic cylinder | With the directional control valve spool in the neutral position and with the valves in the hydraulic system in serviceable condition (item 12.6.2.7) |
| Other characteristics of the hydraulic drive | — | Measured as necessary (item 12.6.2.8) |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| "XADO revitalizant gel for compressors and bearings (industrial)" | 3.0 ml of revitalizant gel per 1 litre of standard oil for one treatment stage | Spindle unit and speed gearbox of lathe-group machine tools having a common lubrication system; treatment in three stages without oil change (item 12.1) |
| "XADO revitalizant gel for gearboxes (industrial)" | 3.0 ml of revitalizant gel per 1 litre of standard oil per treatment stage | Mechanisms of speed gearboxes and feed gearboxes with an autonomous lubrication system; treatment in 3 stages without oil change (item 12.2) |
| "XADO revitalizant gel for compressors and bearings (industrial)" | 1.5 ml of gel per 1 litre of standard oil per treatment stage | Spindle units with an autonomous oil lubrication system; three stages without oil change (item 12.3) |
| "XADO revitalizant gel for gearboxes (industrial)" | 9.0 ml of gel per 1 litre of standard oil | Lead screws lubricated with oil; addition to the lubricating oil of the screw pair without oil change (item 12.4) |
| "XADO revitalizant gel for compressors and bearings (industrial)" | 9.0 ml per 1 litre of standard oil for the entire treatment cycle | Guideways of machine tools with a circulating oil lubrication system; addition to the oil bath (item 12.5.1.1) |
| "XADO revitalizant gel for compressors and bearings (industrial)" | 9.0 ml per 1 litre of oil | Guideways of machine tools lubricated with oil periodically from a separate container; dissolution in the lubricating oil (item 12.5.2.1) |
| Revitalizant gel (for guideways, preventive treatment) | 6.0 ml per one litre of lubricating (standard) oil | For preventive purposes, to increase the service life during further operation after treatment, as well as in new machine tools or those with insignificant guideway wear (up to 10%) — once a year, over 200 hours (items 12.5.1.2, 12.5.2.2) |
| "XADO revitalizant gel for power steering (industrial)" | 0.6 ml of gel per 1 litre of working fluid for one treatment stage | Hydraulic systems of machine tools; treatment in 6 stages without oil change (item 12.6.3) |
Treatment stages
- Spindle unit and speed gearbox with a common lubrication system, first stage: in a separate vessel prepare a mixture of oil (1 part gel to 5-10 parts oil), heated to 40 - 60°C, with the calculated amount of "XADO revitalizant gel for compressors and bearings (industrial)" at the rate of 3.0 ml of gel per 1 litre of standard oil in the machine tool; mix until homogeneous; with the machine tool switched off, add the mixture into the machine tool lubrication system; switch on the machine tooltotal operation for 8 hours in the normal operating mode
- The second and third stages of treatment of the spindle unit and the speed gearbox are carried out in the same way as the first stageat an interval of 8 - 12 hours of total operating time of the machine tool under normal operating conditions
- The treatment of the speed gearbox and the spindle unit is deemed completed; new spindle units or those with wear of up to 10% are treated by this procedure in 2 stagesafter 450 hours of total operating time of the machine tool, counted from the beginning of the first stage
- Speed gearboxes and feed gearboxes with an autonomous lubrication system, first stage: in a separate vessel prepare a mixture of oil (1 part gel to 5-10 parts oil), heated to 40 - 60°C, with "XADO revitalizant gel for gearboxes (industrial)" at the rate of 3.0 ml of gel per 1 litre of standard oil in the machine tool; mix until homogeneous; with the machine tool switched off, add the mixture into the machine tool lubrication system; switch on the machine tooltotal operating time of 8-12 hours in the normal operating mode
- The second and third stages of treatment of the speed and feed gearboxes are carried out in the same way as the first stageat an interval of 8-12 hours of total operating time of the machine tool under normal operating conditions
- The treatment of the speed gearbox and (or) the feed gearbox is deemed completed; new spindle units (or those with wear of up to 10%) are treated by this procedure in 2 stagesafter 450 hours of total operating time of the machine tool, counted from the beginning of the first stage
- Spindle units with an autonomous lubrication system, first stage: in a separate vessel prepare a mixture of oil (1 part gel to 5-10 parts oil), heated to 40 - 60°C, with XADO revitalizant gel for compressors and bearings (industrial) at the rate of 1.5 ml of gel per 1 litre of standard oil in the machine tool; mix until homogeneous; with the machine tool switched off, add the mixture into the spindle lubrication system; switch on the machine tooltotal operation for 8-12 hours in the normal operating mode
- The second and third stages of treatment of the spindle unit are carried out in the same way as the first stageat an interval of 8-12 hours of total operating time of the machine tool under normal operating conditions
- The treatment of the speed gearbox and the spindle unit is deemed completed; new spindle units (or those with a degree of wear of up to 10%) are treated by this procedure in 2 stagesafter 450 hours of total operating time of the machine tool, counted from the beginning of the first stage
- Lead screws: add "XADO revitalizant gel for gearboxes (industrial)" into the lubricating oil of the screw pair at the rate of 9.0 ml of gel per 1 litre of standard oil, without oil change; the treatment is deemed completedafter 550 hours of total operating time
- Guideways with a circulating lubrication system: add into the oil bath "XADO revitalizant gel for compressors and bearings (industrial)" at the rate of 9.0 ml per 1 litre of standard oil for the entire treatment cycle; after the measurements and the addition of the gel, start the machine tool and operate it in the normal modethe full treatment cycle of the guideways — not less than 700 hours of total operating time of the machine tool
- Guideways with periodic manual lubrication: dissolve "XADO revitalizant gel for compressors and bearings (industrial)" in the lubricating oil at the rate of 9.0 ml per 1 litre of oil; lubricate the guideways with the resulting compound and start the machine tool in the normal operating mode; periodic lubrication throughout the treatment cycle — not less than twice per shift or once every 4 hours of machine tool operationthe full treatment cycle of the guideways — not less than 700 hours of total operating time of the machine tool
- Preventive treatment of the guideways (including of new machine tools or those with insignificant guideway wear of up to 10%) at a revitalizant gel consumption rate of 6.0 ml per one litre of lubricating (standard) oilonce a year, over 200 hours of operation
- Hydraulic system, first stage: prepare "XADO revitalizant gel for power steering (industrial)" at the rate of 0.6 ml of gel per 1 litre of working fluid; pour into a separate container the working fluid of the hydraulic system (1 part of the gel being dissolved to 5 -10 parts of oil), heated to 40 - 60°C, add the prepared amount of gel, mix thoroughly until homogeneous and add into the working fluid tank; switch on the hydraulic system, provide a pressure load of up to 50% of the maximum permissible; then continue operating the hydraulic system at the nominal load in the normal modeoperation under a load of up to 50% of the maximum permissible for 1 - 2 hours
- Carry out the second, third, fourth, fifth and sixth stages of treatment of the hydraulic system in the same way as the first stage, at the normal load of the hydraulic driveat an interval of 8-12 hours of total operation of the hydraulic system
- Full treatment cycle of the hydraulic system; the treatment of new hydraulic machines or those with initial wear (up to 10%) is carried out by the above procedure in 4 stages550 hours of total operating time
After treatment
- After completion of the full treatment cycle, measurements of the principal operating parameters of each assembly and of the geometric dimensions of the parts are taken again — the same as before the start of the treatment — in order to determine the effectiveness of the application of the XADO revitalizant compounds.
- For spindle units and speed gearboxes the following are recorded: axial and radial run-out of the spindle mounting surfaces, radial and axial play of the bearings, vibration level of the bearing assemblies, power consumption (current) of the electric motor, surface roughness of the workpiece, taper and ovality of the control workpiece, thickness of the marked teeth, condition of the tooth contact patterns, noise level.
- For lead screws, the axial play in the "screw-nut" pair is recorded.
- For guideways, flatness and straightness are recorded (with special control straightedges or prisms).
- For hydraulic systems the following are recorded: pressure, operating temperature of the working fluid, output (delivery) of the hydraulic pumps, volume of working fluid internal leakage during hydraulic motor operation, vibration level of the hydraulic machine and, if necessary, other characteristics of the hydraulic drive.
- For preventive purposes and to increase the service life after the treatment of the guideways, it is recommended to carry out the treatment once a year, over 200 hours, at a consumption rate of 6.0 ml of revitalizant gel per one litre of oil.
Points to watch
- Before the start of the treatment, it is necessary to eliminate oil leaks (item 12.1.1) and working fluid leaks in the hydraulic system (item 12.6.1).
- The prepared mixture is added with the machine tool switched off.
- Only serviceable assemblies and mechanisms having no completely worn or damaged parts are subject to treatment.
- If the guideways have wear or damage of the working surface deeper than 0.1 mm, it is recommended, before treatment by the XADO technology, to eliminate these defects by machining (planing, grinding), and only then to carry out the treatment with the appropriate XADO revitalizant compound.
- Note to items 12.1 and 12.2: XADO revitalizants have no adverse effect on the operation of friction clutches working in the oil bath of the speed gearboxes (in item 12.2 — "have no effect whatsoever").
- Note: topping up the oil in the oil bath of the spindle unit, the speed gearbox and the feed gearboxes is carried out in accordance with the technical operating rules.
- Note: topping up the lubricating oil for the lead screws and for the guideways is carried out as it is consumed, in accordance with the technical operating rules of the machine tool.
- Treatment of machine tool guideways with XADO revitalizant compounds makes it possible to replace one of the types of finishing operations for guideways — scraping; the treatment of guideways is most effective for preventive purposes: it makes it possible to protect against wear, to increase the microhardness of the working friction surfaces to 750 kg/mm, and also to ensure high corrosion resistance.
Instruction appendices
Compounds for these units
- Revitalizant gel for compressors and bearingsPiston, screw and centrifugal compressors; rolling and sliding bearings running in an oil bath; machine-tool spindle units and slideways.
- Revitalizant gel for gearboxesIndustrial gearboxes, final and central drives, truck and tractor gearboxes, open gear and chain drives.
- Revitalizant gel for hydraulic systemsHydraulic systems of industrial and special equipment, pumps, motors and valves; gearboxes with oil filtration.
Source: Instructions for the use of XADO revitalizant gels IE-24.6-25612000-005-2008, pages 20–26.