Surface grinding machines
The hydraulic system, the grinding head spindle bearings and the ways of the surface grinding machine are subject to treatment. The purpose is restorative repair and protection of friction surfaces against wear without stopping the machine for repair and without disassembly.
Procedure for treating surface grinding machines with XADO revitalizant gel
What is treated
- Serviceable assemblies and mechanisms of grinding-group machines that have no completely worn or damaged parts
- The hydraulic system of the machine
- Grinding head spindle bearings operating in an oil bath
- The ways of the machine
- Ways that have no wear in the form of "saddling", protrusions, or other damage of the working surface deeper than 0.1 mm
- New hydraulic machines or those with initial wear (up to 10%) — treatment by the same procedure in 3 stages
- New spindle assemblies (or those with a degree of wear up to 10%) — treatment by this procedure in 2 stages
- Ways with a centralized circulating oil lubrication system
- Ways with periodic manual oil lubrication (from a separate oil container)
When treatment is not performed
- Assemblies and mechanisms having completely worn or damaged parts are not subject to treatment
- If the ways have wear or damage of the working surface deeper than 0.1 mm, it is recommended to eliminate these defects by machining (planing, grinding) before treatment by the XADO technology, and only then to carry out treatment with the appropriate formulation
- In the text of the procedure the types of way lubrication are listed, including lubrication with greases, but the treatment sequence is described only for the centralized circulating oil lubrication system and for periodic manual oil lubrication
Preparation
- Before starting treatment of the hydraulic system with XADO revitalizant, leaks of the working fluid must be eliminated
- Before the start and after completion of the full treatment cycle, take measurements of the main operating parameters of the hydraulic system and of the bearing assembly
- By visual inspection of all friction surfaces of the ways, determine their technical condition (presence of pits, chips, scoring), the degree of wear and the advisability of treatment by the XADO technology
- Before and after treatment of the ways, measurements of flatness and straightness of the machine ways are taken with special inspection straightedges or prisms (for the circulating lubrication system — if necessary)
- Prepare the mixture: pour into a separate container working fluid (oil) at the rate of 1 part of the gel being dissolved to 5–10 parts of oil, heated to 40 – 60 °C, add the prepared amount of gel and mix thoroughly until uniform
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Pressure in the hydraulic system | Calibrated pressure gauge | Measurements at a fixed working fluid temperature |
| 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 |
| Delivery (flow rate) of the hydraulic pumps | Flow meters | At a fixed pressure and temperature of the working fluid |
| 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 constant temperature of the working fluid at the hydraulic motor outlet |
| Vibration level of the hydraulic machine | Vibration meter | At specified points under fixed operating modes of the hydraulic system |
| Delivery of the hydraulic pumps of power hydraulic systems (indirectly — by the actuation speed of the power mechanism) | Timing of fixed travels of the power hydraulic cylinders | At constant pressure and operating oil temperature |
| Hydraulic tightness of the directional control valves (indirectly) | Comparison of the travel of a loaded serviceable power hydraulic cylinder | With the valve spool in the neutral position and with the valves in the hydraulic system in serviceable condition |
| Other load and adjustment characteristics of the hydraulic drive | — | If necessary |
| Amount of axial and radial run-out of the spindle seating surfaces | Indicator stand with a measuring dial indicator, graduation not coarser than 0.01 mm | By rotating the unloaded shaft with the indicator stylus set on its radial and (or) end surface and reading the indicator |
| Radial and axial play (clearance) of the spindle bearings | Stand with a measuring dial indicator, graduation not coarser than 0.01 mm | By forcibly displacing the spindle in the radial or axial direction towards the stylus of the indicator set on the seating (radial or end) surface of the spindle, and reading the indicator |
| Vibration level of the bearing assemblies (vibration acceleration, vibration velocity, vibration displacement) | Vibration meters of various types | In idle mode with the spindle unloaded, at fixed points of the bearing assembly housing in the vertical, horizontal and axial direction of each bearing support |
| Power consumption or current consumed by the electric motor | Electricity meter, clamp meter, wattmeter or multimeter for measuring electrical circuit parameters | In idle mode and under a fixed load (fixed cutting conditions) at the same oil temperature |
| Surface roughness of a workpiece machined with the same tool under the same cutting conditions | Profilometer or profilometer-profilograph of any type | — |
| Out-of-flatness of the ground surface of a part produced with the same tool under the same cutting conditions | Inspection straightedges and a set of feeler gauges No. 1, or movement of an indicator stand over a surface plate | — |
| Flatness and straightness of the machine ways | Special inspection straightedges or prisms | Before and after treatment |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| XADO revitalizant gel for power steering (industrial) | 0.6 ml of gel per 1 litre of working fluid for one treatment stage | Machine hydraulic system; 6 stages without oil change |
| Hydraulic system working fluid for dissolving the gel | 1 part of the gel being dissolved to 5 - 10 parts of oil, heated to 40 - 60 °C | Preparation of the mixture in a separate container |
| XADO revitalizant gel for compressors and bearings (industrial) | 1.5 ml of gel per 1 litre of the standard oil per treatment stage | Grinding head spindle bearings operating in an oil bath; three stages without oil change |
| Oil for dissolving the gel (spindle bearings) | 1 part of the gel being added to 5-10 parts of oil, heated to a temperature of 40 - 60 °C | First treatment stage, preparation of the mixture in a separate vessel |
| XADO revitalizant gel for compressors and bearings (industrial) | 9.0 ml per 1 litre of the standard oil for the entire treatment cycle | Ways of machines with a circulating oil lubrication system; addition into the oil bath |
| XADO revitalizant gel for compressors and bearings (industrial) | 9.0 ml per 1 litre of oil | Ways lubricated with oil periodically by hand (from a separate container); dissolving in the lubricating oil |
| Revitalizant gel (preventive treatment of the ways) | 6.0 ml per one litre of the standard oil | Once a year, over 200 hours of operation: after treatment, as well as in new machines or those with slight wear of the ways (up to 10%) |
Treatment stages
- Hydraulic system, first stage: prepare "XADO revitalizant gel for power steering (industrial)" at the rate of 0.6 ml per 1 l of working fluid, dissolve it in working fluid heated to 40 - 60 °C (1 part of gel to 5 - 10 parts of oil), mix thoroughly until uniform and add into the working fluid tank. Switch on the hydraulic system, provide pressure loading up to 50% of the maximum permissible; then continue operation at rated load in the standard mode1 - 2 hours at a load up to 50% of the maximum permissible, then the standard mode
- Hydraulic system, second stage — same as the first stage, at the standard load of the hydraulic driveinterval of 8-12 hours of total operation of the hydraulic system
- Hydraulic system, third stage — same as the first stage, at the standard load of the hydraulic driveinterval of 8-12 hours of total operation of the hydraulic system
- Hydraulic system, fourth stage — same as the first stage, at the standard load of the hydraulic driveinterval of 8-12 hours of total operation of the hydraulic system
- Hydraulic system, fifth stage — same as the first stage, at the standard load of the hydraulic driveinterval of 8-12 hours of total operation of the hydraulic system
- Hydraulic system, sixth stage — same as the first stage, at the standard load of the hydraulic driveinterval of 8-12 hours of total operation of the hydraulic system; the full treatment cycle of the hydraulic system is 550 hours of total operating time
- Spindle bearings, first stage: take into a separate vessel a small amount of oil (1 part of the gel being added to 5-10 parts of oil) heated to 40 - 60 °C, add the calculated amount of XADO revitalizant gel for compressors and bearings (industrial) at the rate of 1.5 ml per 1 l of the standard oil in the machine, mix thoroughly until uniform; with the machine not running, add the prepared mixture into the spindle lubrication system; switch on the machine and ensure operation in the standard modetotal operation of 8-12 hours in the standard mode
- Spindle bearings, second stage — same as the first stageinterval of 8-12 hours of total operating time of the machine in the standard operating mode
- Spindle bearings, third stage — same as the first stageinterval of 8-12 hours of total operating time of the machine; the treatment is considered completed after 450 hours of total machine operating time from the beginning of the first stage
- Ways with a centralized circulating lubrication system: after visual inspection of the friction surfaces and measurements, add into the oil bath the required amount of "XADO revitalizant gel for compressors and bearings (industrial)" at the rate of 9.0 ml per 1 l of the standard oil for the entire treatment cycle, start the machine and operate it in the standard modethe full treatment cycle of the ways — not less than 600 hours of total machine operating time
- Ways with periodic manual lubrication: after visual inspection and measurements, dissolve "XADO revitalizant gel for compressors and bearings (industrial)" in the lubricating oil at the rate of 9.0 ml per 1 l of oil, lubricate the ways with the resulting compound and start the machine in the standard operating mode; carry out periodic lubrication not less than twice per shift or once every 4 hours of machine operationthe full treatment cycle of the ways — not less than 700 hours of total machine operating time
After treatment
- After completion of the full treatment cycle, take measurements of the main operating parameters of the hydraulic system (the same as before the start of treatment)
- After completion of the full treatment cycle, take measurements of the main operating parameters of the spindle bearing assembly (the same as before the start of treatment)
- After treatment of the ways, take measurements of flatness and straightness of the machine ways with special inspection straightedges or prisms
- The full treatment cycle of the hydraulic system is 550 hours of total operating time
- Treatment of the gearbox and the spindle assembly is considered completed after 450 hours of total machine operating time, counted from the beginning of the first stage
- The full treatment cycle of the ways is not less than 600 hours of total machine operating time (circulating lubrication system) and not less than 700 hours (periodic manual lubrication)
- For preventive purposes, in order to increase service life during further operation, it is recommended once a year, over 200 hours, to carry out treatment of the ways at a revitalizant gel consumption rate of 6.0 ml per one litre of the standard oil
- Lubricating oil is topped up as it is consumed, in accordance with the technical operating rules of the machine
Points to watch
- Treatment of the hydraulic system and of the spindle bearings is carried out without an oil change
- At the first stage of hydraulic system treatment, pressure loading is provided up to 50% of the maximum permissible for 1 - 2 hours
- The mixture of gel and oil is added into the spindle lubrication system with the machine not running
- Periodic lubrication of the ways throughout the treatment cycle is carried out not less than twice per shift or once every 4 hours of machine operation
- Treatment of the ways with XADO revitalizant formulations makes it possible to replace one of the types of finishing of the ways — scraping
- XADO treatment of the ways is most effective for preventive purposes: it protects against wear, increases the microhardness of the working friction surfaces up to 750 kgf/mm², and also provides high corrosion resistance
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 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 31–35.