Internal grinding machines
The hydraulic system, the chuck headstock mechanism and spindle bearings, the tailstock spindle bearings and the ways of the internal grinding machine are subject to treatment. The purpose is restorative repair and wear protection without taking the machine out of service for repair and without disassembling the units.
Procedure for treating internal grinding machines with XADO revitalizant gel
What is treated
- Serviceable units and mechanisms of internal grinding machines that have no fully worn or damaged parts: the hydraulic system; the chuck headstock mechanism and spindle bearings; the tailstock spindle bearings; the machine ways.
- Hydraulic systems of internal grinding machines — treatment with "XADO revitalizant gel for power steering (industrial)" in 6 stages without oil change.
- New hydraulic machines or those with initial wear (up to 10%) — treatment by the same procedure in 3 stages.
- The chuck headstock mechanism and the spindle operating in an oil bath — treatment with "XADO revitalizant gel for compressors and bearings (industrial)" in three stages without oil change.
- New spindle units or those with wear up to 10% — treatment by the specified procedure in 2 stages.
- Machine ways that have no wear in the form of "saddle-shaped" depressions, protrusions, or other damage to the working surface deeper than 0.1 mm.
- Ways with a centralized circulating oil lubrication system — with "XADO revitalizant gel for compressors and bearings (industrial)" introduced into the oil bath.
- Ways lubricated with oil periodically by hand (from a separate oil container) — with "XADO revitalizant gel for compressors and bearings (industrial)" dissolved in the lubricating oil.
- Preventive treatment of ways in new machines or with insignificant wear of the ways (up to 10%), as well as to extend service life after treatment with XADO revitalizants.
When treatment is not performed
- Units and mechanisms having fully worn or damaged parts are not subject to treatment.
- Ways with wear in the form of "saddle-shaped" depressions, protrusions and other damage to the working surface deeper than 0.1 mm are not subject to treatment — it is recommended to eliminate such defects beforehand by machining (planing, grinding).
- Before starting treatment of the hydraulic system, working fluid leaks must be eliminated; before treating the chuck headstock mechanism and the spindle — oil leaks.
Preparation
- Eliminate working fluid leaks in the hydraulic system before starting treatment with XADO revitalizant.
- Eliminate oil leaks before starting treatment of the chuck headstock mechanism and the spindle.
- Take measurements of the main operating parameters of the hydraulic system before starting treatment and after completing the full treatment cycle.
- Take measurements of the main operating parameters of each unit, as well as the geometric dimensions of the parts, before starting treatment and after completing the full treatment cycle.
- 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 XADO technology.
- Eliminate defects of the ways deeper than 0.1 mm by machining (planing, grinding), and then carry out treatment with the appropriate compound — XADO revitalizant.
- Prepare the calculated amount of gel; pour working fluid (oil) into a separate container (vessel) at a ratio of 1 part gel being dissolved to 5 - 10 parts oil, heated to 40 - 60°C, add the prepared amount of gel and mix 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 other standard instrument for measuring temperature | Before starting treatment and after completing the full treatment cycle |
| Output (delivery) of the hydraulic pumps | Flow meters | Measurements are taken at 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 fixed pressure and constant working fluid temperature at the hydraulic motor outlet |
| Vibration level of the hydraulic machine | Vibrometer | Measurements 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) | Measurement of the time 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 load and adjustment characteristics of the hydraulic drive | — | Measured as required |
| Axial and radial run-out 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 indicator stylus 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) | Vibrometers of various types | In idle mode with the spindle unloaded, 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 | Clamp meter, wattmeter or multi-purpose instrument 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 of any type | Before starting treatment and after completing the full treatment cycle |
| Taper and ovality of a control workpiece produced with the same tool under the same cutting conditions | Bore gauge with a dial indicator with a graduation value no coarser than 0.01 mm | Before starting treatment and after completing the full treatment cycle |
| Thickness of the selected and marked gear teeth of the gearbox | Gear tooth calipers of any type with a graduation value no coarser than 0.05 mm | Take measurements of the tooth thickness of the gear wheels (see appendix 3) |
| Technical condition of the contact patterns of the marked gear wheel teeth | Visually or by means of a camera | The presence and dimensions of damage are recorded |
| Noise level | Sound level meters of any type | At a fixed distance from the noise source, in the absence of extraneous noise sources and under fixed machine operating modes |
| Flatness and straightness of the machine ways | Special inspection straightedges or prisms | Before treatment and after it (after completion of the full cycle), if necessary |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| XADO revitalizant gel for power steering (industrial) | 0.6 ml of gel per 1 liter of working fluid | Hydraulic system of the internal grinding machine, for one treatment stage; 6 stages in total without oil change |
| XADO revitalizant gel for compressors and bearings (industrial) | 3.0 ml of revitalizant gel per 1 liter of standard oil | The chuck headstock mechanism and the spindle operating in an oil bath, for one treatment stage; three stages in total without oil change |
| XADO revitalizant gel for compressors and bearings (industrial) | 9.0 ml per 1 liter of standard oil | Ways with a centralized circulating oil lubrication system; introduction into the oil bath for the entire treatment cycle |
| XADO revitalizant gel for compressors and bearings (industrial) | 9.0 ml per 1 liter of oil | Ways lubricated with oil periodically by hand; dissolution of the gel in the lubricating oil |
| XADO revitalizant gel (for compressors and bearings, industrial) | 6.0 ml per one liter of standard oil | Preventive treatment of the ways once a year over 200 hours — to extend service life after treatment, as well as in new machines or those with insignificant wear of the ways (up to 10%) |
| Dissolution of the gel (for all compounds) | 1 part gel being dissolved to 5 - 10 parts oil | Oil (working fluid) heated to 40 - 60°C |
Treatment stages
- Hydraulic system, first stage: prepare "XADO revitalizant gel for power steering (industrial)" at a rate of 0.6 ml of gel per 1 liter of working fluid; pour hydraulic system working fluid into a separate container (1 part gel being dissolved to 5 - 10 parts oil), heated to 40 - 60°C, add the prepared amount of gel, mix thoroughly until homogeneous and introduce into the working fluid tank. Switch on the hydraulic system, provide a pressure load of up to 50% of the maximum permissible and run for 1 - 2 hours, then continue operation at rated load in standard mode.1 - 2 hours under a load of up to 50% of the maximum permissible, then standard mode
- Hydraulic system, second, third, fourth, fifth and sixth stages: carry out in the same way as the first stage at the standard load of the hydraulic drive.Interval of 8-12 hours of total hydraulic system operation between stages
- Hydraulic system: completion of the full treatment cycle.550 hours of total operating time
- Chuck headstock mechanism and spindle, first stage: take a small amount of oil into a separate vessel (1 part gel being introduced to 5-10 parts oil), heated to 40 - 60°C, add the calculated amount of "XADO revitalizant gel for compressors and bearings (industrial)" (3.0 ml of gel per 1 liter of standard oil in the machine), mix thoroughly until homogeneous; with the machine not running, introduce the prepared mixture into the machine's lubrication system; switch on the machine and provide total operation in standard mode.8 hours of total operation in standard mode
- Chuck headstock mechanism and spindle, second and third stages: carry out in the same way as the first stage.Interval of 8 - 12 hours of total machine operating time under standard operating conditions
- Chuck headstock mechanism and spindle: treatment of the gearbox and the spindle unit is considered complete.450 hours of total machine operating time, counted from the beginning of the first stage
- Ways with a centralized circulating lubrication system: after visual inspection of the friction surfaces and measurements of flatness and straightness, introduce the required amount of gel (9.0 ml per 1 liter of standard oil for the entire cycle) into the oil bath, put the machine into operation and operate it in standard mode.Full treatment cycle of the ways — at least 600 hours of total machine operating time
- Ways with periodic manual oil lubrication: after visual inspection of the friction surfaces and measurements of flatness and straightness, dissolve the gel in the lubricating oil (9.0 ml per 1 liter of oil), lubricate the ways with the resulting compound and put the machine into operation in standard mode; periodic lubrication of the ways throughout the treatment cycle is to be carried out at least twice per shift or once every 4 hours of machine operation.Full treatment cycle of the ways — at least 700 hours of total machine operating time
- Preventive treatment of the ways (after treatment with XADO revitalizants, in new machines or with insignificant wear of the ways up to 10%): to be carried out once a year at a revitalizant gel consumption rate of 6.0 ml per one liter of standard oil.Over 200 hours of operation
After treatment
- After completing the full treatment cycle, take measurements of the main operating parameters of the hydraulic system (the same as before treatment) to determine the effectiveness of the application of XADO compounds.
- After completing the full treatment cycle, take measurements of the main operating parameters of each unit, as well as the geometric dimensions of the parts.
- After completion of the full treatment cycle of the ways, take measurements of the flatness and straightness of the machine ways with special inspection straightedges or prisms.
- Topping up oil in the oil bath of the spindle unit is to be carried out in accordance with the technical operating rules.
- Topping up lubricating oil is to be carried out as it is consumed, in accordance with the technical operating rules of the machine.
- For preventive purposes and to extend service life during further operation after treatment with XADO revitalizants, treat the ways once a year over 200 hours at a consumption rate of 6.0 ml of revitalizant gel per one liter of standard oil.
Points to watch
- Before starting treatment with XADO revitalizant, working fluid leaks (hydraulic system) and oil leaks (chuck headstock mechanism and spindle) must be eliminated.
- At the first stage of hydraulic system treatment, a pressure load of up to 50% of the maximum permissible is provided for 1 - 2 hours, after which operation is carried out at rated load in standard mode.
- If the ways 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 by XADO technology.
- XADO revitalizants have no adverse effect on the operation of friction clutches operating in the oil bath of gearboxes.
- Treatment of machine ways with XADO revitalizant compounds makes it possible to replace one of the types of finishing operations for the ways — scraping.
- XADO treatment of machine ways is most effective as a preventive measure: it protects against wear, increases the microhardness of the working friction surfaces to 750 kg/mm², and also provides 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 38–42.