Centerless Grinding Machines
The treatment applies to serviceable mechanisms of centerless grinding machines: the hydraulic system, the mechanisms of the grinding wheel head and the regulating wheel head, the gearbox of the dressing unit and the speed gearbox mechanism. The purpose is restorative repair and wear protection through staged introduction of the gel into the standard oil without changing the oil and without disassembly.
Procedure for Treating Centerless Grinding Machines with XADO Revitalizant Gel
What is treated
- Any serviceable mechanism of centerless grinding machines that has no parts with 100% wear or mechanical damage
- The hydraulic system of the machine
- Mechanisms of the grinding wheel head; the mechanism of the grinding wheel head and the regulating wheel head operating in an oil bath
- The gearbox of the dressing unit and the speed gearbox mechanism
- XADO revitalizants may be used on serviceable gearboxes that have no parts with 100% wear or macro-mechanical damage
- New hydraulic systems or those with initial wear (up to 10%) — according to the specified procedure, in 3 stages
- New spindle units or those with wear up to 10% — according to the specified procedure, in 2 stages
- New gearboxes or gearboxes with insignificant wear (up to 10%) — in 2 stages at a rate of 3.0 ml of gel per treatment stage or, in the case of a single application, at a rate of 6.0 ml of gel per liter of standard oil
When treatment is not performed
- Mechanisms having parts with 100% wear and mechanical damage are not treated
- Gearboxes having parts with 100% wear and macro-mechanical damage are not treated
Preparation
- Before beginning treatment of the hydraulic system with XADO revitalizant, eliminate leaks of the working fluid
- Before beginning treatment of the grinding wheel head mechanism, eliminate oil leaks
- Before carrying out treatment of the gearbox, eliminate oil leaks
- Before the start of treatment and after completion of the full cycle, take measurements of the main operating parameters (hydraulic system, grinding wheel head units, gearbox)
- Prepare the mixture in a separate container: working fluid (standard oil) heated to 40 - 60°C, at a ratio of 1 part of the gel being dissolved to 5 - 10 parts of oil; mix the components thoroughly until the mixture is uniform
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Pressure in the hydraulic system | Calibrated pressure gauge | At a fixed working fluid temperature; before the start and after completion of the full treatment cycle |
| Operating temperature of the oil (hydraulic fluid) in the hydraulic system | Liquid-filled thermometer, infrared pyrometer or another temperature measuring device | Before the start and after completion of the full treatment cycle |
| Output (delivery) of the hydraulic pumps | Flow meters | At a fixed pressure and working fluid 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 constant working fluid temperature at the hydraulic motor outlet |
| Vibration level of the hydraulic machine | Vibrometer | At specified points under fixed operating modes of the hydraulic system |
| 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 (may be determined 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 with the valves in the hydraulic system in serviceable condition |
| Other load and adjustment characteristics of the hydraulic drive | — | If required |
| Axial and radial runout 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 tip 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, graduation not coarser than 0.01 mm | By forcibly displacing the spindle in the radial or axial direction toward the indicator tip 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 on 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 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 a workpiece machined with the same tool at the same cutting modes | Profilometer of any type | Before the start and after completion of the full treatment cycle |
| Taper and ovality of a reference workpiece produced with the same tool at the same cutting modes | Micrometer or lever caliper gauge with a measuring dial indicator, graduation not coarser than 0.01 mm | Before the start and after completion of the full treatment cycle |
| Thickness of the selected and marked gear teeth of the gearbox | Gear tooth calipers of any type with graduation not coarser than 0.05 mm | See appendix 3 |
| Technical condition of the contact patterns of the marked gear teeth | Visually or with a camera | The presence and size 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 |
| Vibration level of the gearbox at fixed points (vibration acceleration, vibration velocity, vibration displacement) | Vibrometer | Recommended at the bearing supports; in the vertical, horizontal and axial directions. Measurements under items 17.3.3.1 - 17.3.3.5 are carried out at a constant torque on the gearbox output shaft |
| Noise level of the gearbox at fixed points | Sound level meter | At a constant torque on the gearbox output shaft |
| Power consumption (or current consumption) of the gearbox drive electric motor | Clamp meter, wattmeter or multimeter for determining electrical parameters | In idle mode and under a fixed load at the same oil temperature |
| Temperature regime of the gearbox oil | Liquid-filled thermometer or non-contact pyrometer | Before the start and after completion of the full treatment cycle |
| Tooth thickness of the gearbox gears | Gear tooth calipers of any type with graduation not coarser than 0.05 mm | See appendix 3 of this instruction |
| Technical condition of the contact patterns of the marked teeth of the gearbox gears | Visually or with a camera | The presence and size of damage are recorded |
| Backlash of the gear mesh (additionally recommended) | A lead plate passed between the gears while the gearbox is rotating; the residual thickness is measured with a micrometer or a thickness gauge with graduation not coarser than 0.01 mm | Before the start and after completion of the full treatment cycle |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| XADO revitalizant gel for power steering (industrial) | 0.6 ml of gel per liter of working fluid for one treatment stage | Hydraulic system of the machine; 6 stages without changing the oil. New hydraulic systems or those with initial wear (up to 10%) — 3 stages |
| XADO revitalizant gel for compressors and bearings (industrial) | 3.0 ml of revitalizant gel per liter of standard oil for one treatment stage | The mechanism of the grinding wheel head and the regulating wheel head operating in an oil bath; three stages without changing the oil. New spindle units or those with wear up to 10% — 2 stages |
| XADO revitalizant gel for gearboxes (in item 17.3.4.1 referred to as "XADO revitalizant gel for transmissions and gearboxes") | 3.0 ml per liter of standard oil for one treatment stage | The gearbox of the dressing unit and the speed gearbox mechanism; 3 stages without changing the oil. New ones or those with wear up to 10% — 2 stages at a rate of 3.0 ml of gel per stage or a single application of 6.0 ml of gel per liter of standard oil |
| Mixture for introduction (all formulations) | 1 part of the gel being dissolved to 5 - 10 parts of oil heated to 40 - 60°C | Prepared in a separate container, mixed thoroughly until uniform |
Treatment stages
- Hydraulic system, first stage: prepare "XADO revitalizant gel for power steering (industrial)" at a rate of 0.6 ml per liter of working fluid; in a separate container dissolve it in the hydraulic system working fluid (1 part gel to 5 - 10 parts oil) heated to 40 - 60°C; mix thoroughly and add to the working fluid tank; switch on the hydraulic system, provide a pressure load of up to 50% of the maximum permissible, then continue operation at rated load in the standard mode1 - 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: carried 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
- Grinding wheel head mechanism, first stage: pour a small amount of oil into a separate vessel (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)" (3.0 ml of gel per liter of standard oil in the machine), mix thoroughly until uniform; with the machine stopped, introduce the prepared mixture into the machine's lubrication system; switch on the machinetotal operation of 8 hours in the standard mode
- Grinding wheel head mechanism, second and third stages: carried out in the same way as the first stage under standard operating conditionsat intervals of 8 - 12 hours of total machine operating time
- Gearbox of the dressing unit and the speed gearbox mechanism, first stage: pour a small amount of standard oil heated to 40 - 60°C into a separate vessel (1 part of the gel being dissolved to 5 - 10 parts of oil), add the calculated amount of gel (3.0 ml per liter of standard oil for one stage), mix thoroughly until uniform; with the equipment stopped, open the hatch or the oil filler opening, introduce the mixture into the working cavity of the gearbox or directly onto the working surfaces of the gears, close and secure the hatch, and start the unittotal gearbox operating time of 8 -12 hours
- Gearbox, second and third stages: carried out in the same way as the firstafter 8 -12 hours of total operating time at each stage
After treatment
- After completion of the full treatment cycle, repeat the measurements of the main operating parameters of the hydraulic system, the parameters of the grinding wheel head units and the operating characteristics of the gearbox — in order to determine the effectiveness of the XADO formulations
- The full treatment cycle of the hydraulic system amounts to 550 hours of total operating time
- Treatment of the gearbox and the spindle unit with XADO revitalizant is considered complete after 450 hours of total machine operating time, counted from the beginning of the first stage
- Treatment of the gearbox is considered complete after 450 hours of total operating time, counted from the beginning of the first treatment stage
- The following are recorded: spindle runout and play, vibration and noise levels, power consumption (current) of the electric motor, roughness, taper and ovality of the reference workpiece, tooth thickness and condition of the gear contact patterns, temperature and pressure of the working fluid
Points to watch
- Treatment of all units is carried out without changing the oil
- Before treatment, leaks of the working fluid (oil) must be eliminated
- At the first stage of hydraulic system treatment, the pressure load is provided at up to 50% of the maximum permissible
- XADO revitalizants have no adverse effect on the operation of friction clutches operating in the oil bath of gearboxes
- Topping up the oil in the oil bath of the spindle unit is carried out in accordance with the technical operating rules
- Measurements under items 17.3.3.1 - 17.3.3.5 are carried out at a constant torque on the gearbox output shaft
- The mixture is introduced with the machine (equipment) stopped
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 42–46.