Milling machine group
The procedure describes the treatment with XADO revitalizant gels of milling machine assemblies — the speed gearbox and spindle unit, the feed gearbox with the knee gears and bearings, the lead screws, the guideways and the hydraulic systems. The treatment is carried out without stopping for repair, without disassembly and without changing the oil, by introducing the calculated amount of gel into the standard oil in stages.
Procedure for treating milling group machine tools with XADO revitalizant gel
What is treated
- Any serviceable milling machine mechanisms that have no parts with 100% wear or mechanical damage.
- The speed gearbox mechanism and the spindle unit.
- Spindle heads with grease lubrication.
- The feed gearbox, the knee gears and bearings.
- Cross and longitudinal travel lead screws.
- Machine guideways.
- Hydraulic systems.
- Machine guideways with three types of lubrication: centralized circulating oil lubrication system; grease lubrication; periodic manual oil lubrication.
- Machine guideways that have no wear in the form of "saddling", protrusions, or other damage to the working surface deeper than 0.1 mm.
- Lead screws lubricated with oil.
- New spindle units or those with slight wear (up to 10%) — treated under this procedure in 2 stages.
- New hydraulic machines or those with initial wear (up to 10%) — treated under the specified procedure in 4 stages.
When treatment is not performed
- Mechanisms with parts having 100% wear or mechanical damage are not subject to treatment.
- If the guideways have wear or damage to the working surface deeper than 0.1 mm, it is recommended to eliminate these defects by machining (planing, grinding) before treatment under the XADO technology, and only then to carry out the treatment with the appropriate XADO revitalizant compound.
- Treatment of the hydraulic system is not carried out until the working fluid leaks have been eliminated.
Preparation
- Before starting the treatment of the hydraulic system, eliminate the working fluid leaks.
- 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 under the XADO technology.
- Before and after the treatment, measurements of the flatness and straightness of the machine guideways are taken with special inspection straightedges or prisms (with circulating lubrication — if necessary).
- Take a small amount of oil into a separate vessel at the rate of 1 part of the gel being introduced 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.
- Introduce the mixture into the machine lubrication system with the machine switched off.
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Amount of axial and radial runout of the spindle seating surfaces | Indicator stand with a dial indicator, graduation not coarser than 0.01 mm | By rotating the unloaded spindle with the indicator stylus placed on its radial and (or) end face surface and recording the indicator readings. Before the start and after completion of the full treatment cycle. |
| Radial and axial play (clearance) of the spindle bearings | Stand with a measuring indicator, graduation not coarser than 0.01 mm | By forcibly displacing the spindle in the radial or axial direction towards the indicator stylus placed on the seating (radial or end face) surface of the spindle, and recording the indicator readings. |
| Vibration level of the bearing units | Vibrometers of various types | In idle mode of the unloaded spindle: vibration acceleration, vibration velocity and vibration displacement at fixed points of the bearing unit housing in the vertical, horizontal and axial directions of each bearing support. |
| Power consumption or current consumption of the electric motor (speed gearbox, spindle unit) | Current clamps, wattmeter or multimeter for measuring electrical circuit parameters | In idle mode and at fixed cutting modes, at a fixed load and a fixed oil temperature. |
| Surface roughness of the workpiece | Profilometer or profilometer-profilograph of any type | The workpiece is milled with the same tool at identical cutting modes. |
| Out-of-flatness of the milled surface of the workpiece | Inspection straightedges and a set of feeler gauges No. 1, or a stand with a measuring indicator moved along an inspection plate | The workpiece is made with the same tool at identical cutting modes. |
| Thickness of the selected and marked gear teeth of the speed gearbox and of the gear trains of the feed gearbox | Gear tooth calipers of any type with graduation not coarser than 0.05 mm | Measurement of the gear tooth thickness — see Appendix 3 of this instruction. |
| Technical condition of the contact patterns of the marked gear teeth | Visually or with a camera | The presence and dimensions of damage are recorded. |
| Noise level | Sound level meters of any type | At the same (fixed) distance from the noise source and at fixed machine operating modes, in the absence of extraneous noise sources. |
| Vibration level of the speed gearbox or the feed gearbox | Vibrometers of various types | In idle mode of the unloaded machine spindle: vibration acceleration, vibration velocity and vibration displacement at fixed points of the housing in the vertical, horizontal and axial directions of the bearing support. |
| Power consumption or current consumption of the electric motor (feed gearbox) | Electricity meter, current clamps, wattmeter or multimeter for measuring electrical circuit parameters | In idle mode at the same oil temperature. |
| Axial play in the "screw-nut" pair | — | Before the start of the treatment and after completion of the full treatment cycle of the lead screw. |
| Flatness and straightness of the machine guideways | Special inspection straightedges or prisms | Before and after the treatment. |
| Pressure in the hydraulic system | Calibrated pressure gauge | At a fixed working fluid temperature. |
| Working temperature of the oil (hydraulic fluid) in the hydraulic system | Liquid thermometer, infrared pyrometer or another standard temperature measuring instrument | — |
| Output (delivery) of the hydraulic pumps | Flow meters | At a fixed pressure and working fluid temperature. For power hydraulic systems, the output of the hydraulic pumps is determined indirectly by the actuation speed of the power mechanism: the time of fixed travel of the power hydraulic cylinders is measured at constant pressure and working oil temperature. |
| Volume of working fluid leakage during operation of the hydraulic motors over a fixed period of time | Measuring vessel with a graduated scale | At a fixed pressure and a constant working fluid temperature at the hydraulic motor outlet. |
| Vibration level of the hydraulic machine | Vibrometer | At specified points at fixed operating modes of the hydraulic system. |
| Hydraulic tightness of the directional control valves | — | It is permitted to determine it indirectly by comparing the amount of travel of a loaded serviceable power hydraulic cylinder with the spool of the directional control valve in the neutral position and with the valves in the hydraulic system in serviceable condition. |
| Other characteristics of the hydraulic drive | — | If necessary. |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| XADO revitalizant gel for compressors and bearings (industrial) | 3.0 ml of gel per 1 liter of standard oil for 1 treatment stage | The speed gearbox mechanism and the spindle unit having a common lubrication system; three stages without changing the oil, introduction into the oil bath. |
| XADO revitalizant gel for gearboxes (industrial) | 3.0 ml of revitalizant gel per 1 liter of standard oil per treatment stage | The feed gearbox, the knee gears and bearings with an independent lubrication system; 3 stages without changing the oil. |
| XADO revitalizant gel for gearboxes (industrial) | 9.0 ml of gel per 1 liter of standard oil | Lead screws lubricated with oil; introduction into the lubricating oil of the screw pair without changing the oil. |
| XADO revitalizant gel for compressors and bearings (industrial) | 9.0 ml per 1 liter of standard oil for the entire treatment cycle | Machine guideways with a circulating oil lubrication system; introduction into the oil bath. |
| XADO revitalizant gel for compressors and bearings (industrial) | 6.0 ml per one liter of standard oil | Preventive treatment of guideways with circulating lubrication: once a year, over 200 hours — after the treatment, as well as in new machines or in machines with insignificant guideway wear (up to 10%). |
| XADO revitalizant gel for compressors and bearings (industrial) | 9.0 ml per 1 liter of oil | Machine guideways lubricated with oil periodically (from a separate oil container); dissolution in the lubricating oil. |
| XADO revitalizant gel for compressors and bearings (industrial) | 6.0 ml per one liter of standard oil | Preventive treatment of guideways with manual periodic lubrication: once a year, over 200 hours of operation — after the treatment, as well as in new machines or in machines with insignificant guideway wear (up to 10%). |
| XADO revitalizant gel for power steering (industrial) | 0.6 ml of gel per 1 liter of working fluid for one treatment stage | Hydraulic systems of milling group machines; 6 stages without changing the oil. |
| Oil (working fluid) for preparing the mixture | 1 part of the gel being introduced to 5-10 parts of oil heated to a temperature of 40 - 60°C | Preparation of a homogeneous mixture before introduction into the lubrication system or the working fluid tank. |
Treatment stages
- Speed gearbox and spindle unit, first stage: in a separate vessel prepare a mixture (1 part of gel to 5-10 parts of 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 liter of standard oil in the machine; with the machine switched off, introduce the mixture into the machine lubrication system; switch on the machine.total operation for 8 -12 hours in the standard mode
- Speed gearbox and spindle unit, second stage — same as the first stage.interval of 8 -12 hours of total machine operating time in the standard operating mode
- Speed gearbox and spindle unit, third stage — same as the first stage. The treatment is considered completed after 450 hours of total machine operating time, counted from the beginning of the first stage. New spindle units or those with slight wear (up to 10%) are treated in 2 stages.interval of 8 -12 hours of total operating time; full cycle — 450 hours of total machine operating time
- Feed gearbox, knee gears and bearings, first stage: in a separate vessel prepare a mixture (1 part of gel to 5-10 parts of oil heated to 40 - 60°C) with the calculated amount of "XADO revitalizant gel for gearboxes (industrial)" at the rate of 3.0 ml of gel per 1 liter of standard oil in the machine; with the machine switched off, introduce the mixture into the machine lubrication system; switch on the machine.total operating time of 8-12 hours in the standard mode
- Feed gearbox, second stage — same as the first stage.interval of 8-12 hours of total machine operating time in the standard operating mode
- Feed gearbox, third stage — same as the first stage. The treatment of the speed gearbox and (or) the feed gearbox is considered completed after 450 hours of total machine operating time, counted from the beginning of the first stage. New spindle units (or those with wear up to 10%) are treated under this procedure in 2 stages.interval of 8-12 hours of total operating time; full cycle — 450 hours of total machine operating time
- Lead screws: introduction of "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 liter of standard oil, without changing the oil.the treatment is considered completed after 550 hours of total operating time
- Guideways with a centralized circulating oil lubrication system: inspect the friction surfaces, take measurements of flatness and straightness, introduce "XADO revitalizant gel for compressors and bearings (industrial)" into the oil bath at the rate of 9.0 ml per 1 liter of standard oil for the entire treatment cycle, put the machine into operation and operate it in the standard mode.the full treatment cycle of the guideways — not less than 600 hours of total machine operating time
- Guideways with periodic manual oil lubrication: inspect the friction surfaces, take measurements of flatness and straightness, dissolve "XADO revitalizant gel for compressors and bearings (industrial)" in the lubricating oil at the rate of 9.0 ml per 1 liter of oil, lubricate the guideways with the resulting compound and put the machine into operation in the standard mode. Periodic lubrication throughout the treatment cycle — not less than twice per shift or once every 4 hours of machine operation.the full treatment cycle of the guideways — not less than 700 hours of total machine operating time
- Hydraulic system, first stage: prepare "XADO revitalizant gel for power steering (industrial)" at the rate of 0.6 ml of gel per 1 liter of working fluid for one stage; 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 a homogeneous mixture is obtained and introduce it into the working fluid tank; switch on the hydraulic system, provide a pressure load of up to 50% of the maximum permissible and operate for 1 - 2 hours, then continue operation at the rated load in the standard mode.1 - 2 hours at a load of up to 50% of the maximum permissible, then the standard mode
- Hydraulic system, second, third, fourth, fifth and sixth stages — same as the first stage at the standard load of the hydraulic drive. The treatment of new hydraulic machines or those with initial wear (up to 10%) is carried out under the specified procedure in 4 stages.interval of 8-12 hours of total operation of the hydraulic system; the full treatment cycle of the hydraulic system — 550 hours of total operating time
After treatment
- After completion of the full treatment cycle, repeat the measurements of the main operating parameters and geometric dimensions of each assembly that were taken before the start of the treatment.
- Record the technical condition of the contact patterns of the marked gear teeth visually or with a camera (presence and dimensions of damage).
- After treating the guideways, take measurements of the flatness and straightness of the machine guideways with inspection straightedges or prisms.
- After treating the lead screw, take measurements of the axial play in the "screw-nut" pair.
- For preventive purposes and to increase the service life during further operation, after the treatment it is recommended to treat the guideways once a year, over 200 hours, at a revitalizant gel consumption rate of 6.0 ml per one liter of standard oil.
- Topping up the oil in the oil bath of the speed gearbox, the feed gearboxes and the machine, as well as topping up the lubricating oil, shall be carried out in accordance with the technical operating rules, as it is used up.
Points to watch
- XADO revitalizants have no effect whatsoever on the operation of friction clutches running in the oil bath of the speed gearboxes.
- XADO revitalizants have no effect whatsoever on the operation of friction clutches running in the oil bath (hydraulic systems).
- Topping up the oil in the oil bath of the speed gearbox and the feed gearboxes is carried out in accordance with the technical operating rules.
- Topping up the lubricating oil is carried out in accordance with the technical operating rules (lead screws).
- Topping up the lubricating oil is carried out as it is used up, in accordance with the technical operating rules of the machine (guideways).
- Topping up the oil in the machine oil bath is carried out in accordance with the technical operating rules (hydraulic systems).
- Treating the guideways with XADO revitalizant compounds makes it possible to replace one of the types of finishing treatment of guideways — scraping.
- XADO treatment of machine 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/mm², 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: Instruction for the use of XADO revitalizant gels IE-24.6-25612000-005-2008, pages 26–31.