Cylindrical grinding machines
The hydraulic system, the grinding head and headstock mechanisms and the guideways of the cylindrical grinding machine are subject to treatment. The purpose is restorative repair and wear protection of friction surfaces without shutting the machine down for repair and without disassembly.
Procedure for treating cylindrical grinding machines with XADO revitalizant gel
What is treated
- Any serviceable mechanism of cylindrical grinding machines that has no parts with 100% wear or mechanical damage
- The hydraulic system of the machine
- The grinding head and headstock mechanisms
- The spindle bearings of the grinding head and headstock operating in an oil bath
- The machine guideways
- Guideways with no wear in the form of "saddling", protrusions, or other damage to the working surface deeper than 0.1 mm
- Guideways with a centralized circulating oil lubrication system
- Guideways with periodic manual oil lubrication (from a separate oil container)
- New hydraulic machines or those with initial wear (up to 10%) — according to the stated procedure, in 3 stages
- New spindle units (or with a degree of wear up to 10%) — according to this procedure, in 2 stages
When treatment is not performed
- Mechanisms having parts with 100% wear or mechanical damage are not treated
- If the guideways show 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 using XADO technology, and only then carry out treatment with the appropriate XADO revitalizant compound
- Treatment of the hydraulic system and the spindle units is performed without changing the oil
Preparation
- Before starting treatment with XADO revitalizant, eliminate leaks of the working fluid
- Before starting treatment and after completing the full treatment cycle, take measurements of the main operating parameters of the hydraulic system and of the spindle unit parameters
- 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 using XADO technology
- Before and after treating the guideways, measure the flatness and straightness of the machine guideways with special inspection straightedges or prisms
- Dilute the gel in working fluid (oil) heated to 40 - 60°C at a ratio of 1 part of the gel being dissolved to 5 -10 parts of oil, and stir thoroughly until a homogeneous mixture is obtained
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Pressure in the hydraulic system | Calibrated pressure gauge | Measurements are taken at a fixed working fluid temperature; before starting treatment and after completing the full cycle |
| Operating temperature of the oil (hydraulic fluid) in the hydraulic system | Liquid-filled thermometer, infrared pyrometer or another temperature measuring device | Before starting treatment and after completing the full treatment cycle |
| Output (delivery) of the hydraulic pumps | Flow meters | Measurements are taken at a fixed pressure and working fluid temperature |
| Volume of working fluid 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 |
| Vibration level of the hydraulic machine | Vibration meter | Measurements are taken at specified points under fixed hydraulic system operating modes |
| Output of the hydraulic pumps of power hydraulic systems (indirectly — by the actuation speed of the power mechanism) | Timing of fixed travel of the power hydraulic cylinders | At constant pressure and operating oil temperature |
| Hydraulic tightness of the directional control valves (indirectly) | Comparison of the amount of travel of a loaded, serviceable power hydraulic cylinder | With the directional control valve spool in the neutral position and the valves in the hydraulic system in serviceable condition |
| Other characteristics of the hydraulic drive | — | Measured as required |
| Amount of axial and radial runout of the spindle seating surfaces | Indicator stand with a measuring dial indicator with a graduation value no 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 |
| Radial and axial play (clearance) of the spindle bearings | Stand with a measuring dial indicator with a graduation value no coarser than 0.01 mm | By forcibly displacing the spindle in the radial or axial direction towards the stylus of the indicator placed on the seating (radial or end) surface of the spindle and reading the indicator |
| Vibration level of the bearing units (vibration acceleration, vibration velocity, vibration displacement) | Vibration meters of various types | In idle mode with the spindle unloaded, at fixed points of the bearing unit housing in the vertical, horizontal and axial direction of each bearing support |
| Power consumption or current consumption of the electric motor | Clamp meter, wattmeter or multimeter for measuring electrical circuit parameters | In idle mode and under a fixed load (fixed cutting modes) at the same oil temperature |
| Surface roughness of the workpiece | Profilometer of any type | The workpiece is machined with one and the same tool at identical cutting modes |
| Taper and ovality of the test workpiece | Micrometer or lever snap gauge with a measuring dial indicator with a graduation value no coarser than 0.01 mm | The workpiece is machined with one and the same tool at identical cutting modes |
| Flatness and straightness of the machine guideways | Special inspection straightedges or prisms | Before and after treatment (with circulating lubrication — if necessary) |
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 | Hydraulic system of the cylindrical grinding machine, 6 stages without changing the oil |
| Hydraulic system working fluid for diluting the gel | 1 part of the gel being dissolved to 5 -10 parts of oil heated to 40 - 60°C | The mixture is prepared in a separate container before being added to the tank |
| XADO revitalizant gel for compressors and bearings (industrial) | 1.5 ml of gel per 1 litre of the standard oil for one treatment stage | Spindle bearings of the grinding head and headstock operating in an oil bath; six stages without changing the oil |
| Oil for diluting the gel when treating the spindle unit | 1 part of the gel being added to 5 -10 parts of oil heated to a temperature of 40 - 60°C | The mixture is prepared 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 | Guideways of machines with a centralized circulating oil lubrication system; added to the oil bath |
| XADO revitalizant gel for compressors and bearings (industrial) | 9.0 ml per 1 litre of oil | Guideways lubricated with oil periodically by hand (from a separate container); dissolved in the lubricating oil |
| XADO revitalizant gel (preventive treatment of guideways) | 6.0 ml per one litre of the standard oil | Once a year, over 200 hours of operation — for new machines, with minor guideway wear (up to 10%) and to extend service life after treatment |
Treatment stages
- Hydraulic system, stage 1: prepare "XADO revitalizant gel for power steering (industrial)" at a rate of 0.6 ml per 1 litre of working fluid; pour hydraulic system working fluid heated to 40 - 60°C into a separate container (1 part of gel to 5 -10 parts of oil), add the prepared amount of gel, stir thoroughly until a homogeneous mixture is obtained and add it to the working fluid tank. Switch on the hydraulic system, provide a pressure load of up to 50% of the maximum permissible and run it for 1 - 2 hours, then continue operation at nominal load in the standard mode1 - 2 hours under a load of up to 50% of the maximum permissible, then standard mode
- Hydraulic system, the second, third, fourth, fifth and sixth stages: carry out in the same way as the first stage at the standard load of the hydraulic driveAt intervals of 8-12 hours of total hydraulic system operation; the full treatment cycle of the hydraulic system is 550 hours of total operating time
- Spindle unit, first stage: pour a small amount of oil heated to 40 - 60°C into a separate vessel (1 part of the gel being added to 5 -10 parts of oil), add the calculated amount of XADO revitalizant gel for compressors and bearings (industrial) at a rate of 1.5 ml per 1 litre of the standard oil in the machine, stir thoroughly until a homogeneous mixture is obtained; with the machine stopped, add the mixture to the spindle lubrication system; switch on the machine and ensure operation in the standard modeTotal operation for 8-12 hours in the standard mode
- Spindle unit, second and third stages: carried out in the same way as the first stageAt intervals of 8-12 hours of total machine operating time in standard operation; the treatment is considered complete after 450 hours of total machine operating time, counted from the beginning of the first stage
- Guideways with a centralized circulating lubrication system: inspect the friction surfaces, if necessary measure flatness and straightness, add to the oil bath the required amount of gel at a rate of 9.0 ml per 1 litre of the standard oil for the entire treatment cycle, start the machine and operate it in the standard modeThe full treatment cycle of the guideways is at least 600 hours of total machine operating time
- Guideways with periodic manual lubrication: inspect the friction surfaces, measure flatness and straightness, dissolve the gel in the lubricating oil at a rate of 9.0 ml per 1 litre of oil, lubricate the guideways with the resulting compound and start the machine in the standard mode; during the treatment cycle, periodic lubrication is to be performed at least twice per shift or once every 4 hours of machine operationThe full treatment cycle of the guideways is at least 700 hours of total machine operating time
After treatment
- After completing the full treatment cycle, take measurements of the main operating parameters of the hydraulic system (the same as before treatment)
- After completing the full treatment cycle, take measurements of the main operating parameters of the spindle unit (runout, play, vibration, power or current consumption of the electric motor, roughness, taper and ovality of the test workpiece)
- After treating the guideways, measure the flatness and straightness of the machine guideways with inspection straightedges or prisms
- For preventive purposes, to extend service life during further operation after treatment with XADO revitalizants, it is recommended to treat the guideways once a year, over 200 hours of operation, at a revitalizant gel consumption rate of 6.0 ml per one litre of the standard oil
Points to watch
- Before starting treatment with XADO revitalizant, leaks of the working fluid must be eliminated
- The mixture of gel and oil must be added to the spindle lubrication system with the machine stopped
- Topping up the oil in the oil bath of the spindle unit is performed in accordance with the technical operating rules
- Topping up the lubricating oil for the guideways is performed as it is consumed, in accordance with the technical operating rules of the machine
- Treatment of guideways with XADO revitalizant compounds makes it possible to replace one of the types of guideway finishing — scraping; treatment is most effective for preventive purposes: it protects against wear, increases the microhardness of the working friction surfaces to 750 kg/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 ИЭ-24.6-25612000-005-2008, pages 35–38.