Jig Boring Machines
The procedure describes the treatment of serviceable mechanisms of jig boring machines — the spindle unit, the main drive, the hydraulic system and the ways — with XADO revitalizant gels without oil change and without disassembly. The purpose of the treatment is to restore the working surfaces and protect them from further wear under normal operating conditions.
Procedure for Treating Jig Boring Machines with XADO Revitalizant Gel
What is treated
- Serviceable mechanisms of jig boring machines that have no parts with 100% wear and no mechanical damage
- Spindle unit
- Main drive
- Hydraulic system
- Machine ways
- Ways that have no wear in the form of "saddling", protrusions, or other damage to the working surface deeper than 0.1 mm
- New spindle units (or those with wear up to 10%) — treated according to this procedure in 2 stages
- New hydraulic systems or those with minor wear (up to 10%) — treated according to this procedure in 4 stages
- Ways of machines equipped with a centralized circulating oil lubrication system
- New machines or machines with minor way wear (up to 10%) — preventive treatment of the ways once a year for 200 hours
When treatment is not performed
- Mechanisms having parts with 100% wear and mechanical damage are not subject to treatment
- If the ways 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
- XADO revitalizants have no effect whatsoever on the operation of friction clutches running in the oil bath of gearboxes
Preparation
- Before starting treatment of the hydraulic system, eliminate any working fluid leaks
- Before starting treatment and after completing the full cycle, take measurements of the main operating parameters of the units
- For the ways: by visual inspection of all friction surfaces, determine their technical condition (presence of pits, chips, scoring), the degree of wear and the advisability of treatment using XADO technology
- For the ways: before and after treatment, if necessary, measure the flatness and straightness of the machine ways with special inspection straightedges or prisms
- Spindle unit: pour a small amount of the machine's own oil into a separate clean vessel at a ratio of 5-10 parts of oil to the calculated volume of gel for one treatment stage, and heat it to 50-60°C
- Main drive: take a small amount of oil in a separate vessel (at a ratio of 1 part of the gel being added to 5-10 parts of oil), heated to a temperature of 40-60°C
- Hydraulic system: pour the working fluid of the hydraulic system into a separate container (at a ratio of 1 part of the gel being dissolved to 5-10 parts of oil), heated to 40-60°C
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Axial and radial run-out of the spindle mounting surfaces | Indicator stand with a measuring dial indicator, graduation no coarser than 0.01 mm | Spindle unit. Measurements are taken by rotating the unloaded shaft with the indicator stylus set on its radial and/or end surface and reading the indicator. Before starting treatment and after completing the full cycle |
| Radial and axial play (clearance) of the spindle bearings | Stand with a measuring dial indicator, graduation no coarser than 0.01 mm | Spindle unit. Forced displacement of the spindle in the radial or axial direction toward the stylus of the indicator set on the spindle mounting (radial or end) surface, and reading of the indicator |
| Vibration level of the bearing assemblies (vibration acceleration, vibration velocity, vibration displacement) | Vibration meters of various types | Spindle unit. In idle mode with the spindle unloaded, at fixed points on the bearing housing in the vertical, horizontal and axial directions of each bearing support |
| Power consumption or current drawn by the electric motor | Current clamps, wattmeter or multi-parameter instrument for measuring electrical circuit parameters | Spindle unit. In idle mode and under a fixed load (fixed cutting conditions), at the same oil temperature |
| Surface roughness of the workpiece | Profilometer or profilometer-profilograph of any type | Spindle unit. The workpiece is machined with the same tool under the same cutting conditions |
| Taper and ovality of the test workpiece | Micrometer or lever snap gauge with a measuring dial indicator, graduation no coarser than 0.01 mm | Spindle unit. The workpiece is machined with the same tool under the same cutting conditions |
| Thickness of the selected and marked gear teeth | Gear tooth calipers of any type with a graduation no coarser than 0.05 mm | Main drive. Measurement of the gear tooth thickness (see appendix 3). Before starting treatment and after completing the full cycle |
| Technical condition of the contact patterns of the marked gear teeth | Visually or with a camera | Main drive. The presence and size of damage is recorded |
| Vibration level (vibration acceleration, vibration velocity, vibration displacement) | Vibration meters of various types | Main drive. In idle mode with the machine spindle unloaded, at fixed points on the housing of the gearbox or feed box in the vertical, horizontal and axial directions of the bearing support |
| Power consumption or current drawn by the electric motor | Current clamps, wattmeter or multi-parameter instrument for measuring electrical circuit parameters | Main drive. In idle mode at the same oil temperature |
| Noise level | Sound level meters of any type | Main drive. At a fixed distance from the noise source, with no extraneous noise sources and under fixed machine operating conditions |
| Oil pressure in the hydraulic system | Calibrated pressure gauge | Hydraulic system. At a fixed working fluid temperature. Before starting and after completing the full treatment cycle |
| Operating temperature of the oil (hydraulic fluid) in the hydraulic system | Liquid-in-glass thermometer, infrared pyrometer or other standard temperature measuring instrument | Hydraulic system |
| Output (delivery) of the hydraulic pumps | Flow meters | Hydraulic system. At a fixed pressure and working fluid temperature |
| Vibration level of the hydraulic machines | Vibration meter | Hydraulic system. At specified points under fixed operating conditions of the hydraulic system |
| Output of the hydraulic pumps of power hydraulic systems (indirectly — by the actuating speed of the power mechanism) | Timing of fixed travel distances of the power hydraulic cylinders | Hydraulic system. 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 | Hydraulic system. With the valve spool in the neutral position and the valves in the hydraulic system in serviceable condition |
| Other characteristics of the hydraulic drive | — | Hydraulic system. Measured as required |
| Flatness and straightness of the machine ways | Special inspection straightedges or prisms | Ways. Before and after treatment, if necessary |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| XADO revitalizant gel for power steering (industrial) | 0.8 ml of gel per 1 liter of the machine's own oil for one treatment stage | Spindle units of jig boring machines; 5 stages without oil change |
| XADO revitalizant gel for gearboxes (industrial) | 3.0 ml of revitalizant gel per 1 liter of the machine's own oil for one treatment stage | Main drive; 3 stages without oil change |
| XADO revitalizant gel for power steering (industrial) | 0.6 ml of gel per 1 liter of working fluid for one treatment stage | Hydraulic system; 6 stages without oil change |
| XADO revitalizant gel for compressors and bearings (industrial) | 9.0 ml per 1 liter of the machine's own oil for the entire treatment cycle | Ways of machines equipped with a circulating oil lubrication system; added to the oil bath |
| Revitalizant gel (preventive treatment of the ways) | 6.0 ml per liter of the machine's own oil | Ways: once a year, for 200 hours — after treatment with XADO revitalizants, as well as in new machines or machines with minor way wear (up to 10%) |
Treatment stages
- Spindle unit, first stage: pour a small amount of the machine's own oil into a separate clean vessel at a ratio of 5-10 parts of oil to the calculated volume of gel for one stage; heat the oil by any safe method to a temperature of 50-60°C; add the calculated volume of "XADO revitalizant gel for power steering (industrial)" at a ratio of 0.8 ml of gel per 1 liter of the machine's own oil; mix the blend thoroughly and add it to the spindle oil bath with the machine switched off; switch on the machine and operate it under normal conditions8-12 hours of cumulative operating time until the next stage
- Spindle unit, second, third, fourth and fifth treatment stages — same as the firstcarried out after 8-12 hours of cumulative operating time between stages
- Spindle unit: completion of the full treatment cycle450 hours of cumulative machine operating time, counted from the first treatment stage
- Main drive, first stage: take a small amount of oil in a separate vessel (at a ratio of 1 part of the gel being added to 5-10 parts of oil), heated to a temperature of 40-60°C; add the calculated amount of "XADO revitalizant gel for gearboxes (industrial)" at a ratio of 3.0 ml of gel per 1 liter of the machine's own oil; mix thoroughly until uniform; with the machine switched off, add the mixture to the machine's lubrication system; switch on the machinecumulative operating time of 8-12 hours under normal operating conditions
- Main drive, second and third stages — same as the first stage, under normal operating conditionsinterval of 8-12 hours of cumulative machine operating time
- Main drive: treatment of the gearbox and/or feed box is considered complete450 hours of total machine operating time, counted from the start of the first stage
- Hydraulic system, first stage: prepare "XADO revitalizant gel for power steering" at a ratio of 0.6 ml of gel per 1 liter of working fluid for one stage; pour the working fluid of the hydraulic system into a separate container (at a ratio of 1 part of the gel being dissolved to 5-10 parts of oil), heated to 40-60°C, and add the prepared amount of gel; mix the composition thoroughly until uniform and add it to the working fluid tank; switch on the hydraulic system and provide a pressure load of up to 50% of the maximum permissible; then continue operating the hydraulic system at rated load under normal conditions1-2 hours at a load of up to 50% of the maximum permissible, then normal operating mode
- Hydraulic system, second, third, fourth, fifth and sixth stages — same as the first stage, at the normal load of the hydraulic driveinterval of 8-12 hours of cumulative hydraulic system operation
- Hydraulic system: completion of the full treatment cycle550 hours of cumulative operating time
- Ways (centralized circulating oil lubrication system): by visual inspection of all friction surfaces, determine their technical condition (presence of pits, chips, scoring), the degree of wear and the advisability of treatment; measure the flatness and straightness; add to the oil bath the required amount of "XADO revitalizant gel for compressors and bearings (industrial)" at a ratio of 9.0 ml per 1 liter of the machine's own oil for the entire treatment cycle; start the machine and operate it under normal conditionsthe full treatment cycle of the ways — at least 600 hours of total machine operating time
- Ways, preventive maintenance: treatment at a revitalizant gel consumption rate of 6.0 ml per liter of the machine's own oil — to extend the service life during further operation after treatment, as well as in new machines or machines with minor way wear (up to 10%)once a year, for 200 hours
After treatment
- After completing the full treatment cycle, take repeat measurements of the main operating parameters of the unit (run-out, bearing play, vibration, power consumption or current, roughness, taper and ovality of the workpiece)
- After completing the full treatment cycle of the main drive, take repeat measurements of the thickness of the marked teeth, the condition of the contact patterns, the vibration level, the power consumption (current) and the noise level
- After completing the full treatment cycle of the hydraulic system, take repeat measurements of the pressure, operating temperature, hydraulic pump output and vibration level of the hydraulic machines
- After treatment of the ways, if necessary, measure the flatness and straightness of the ways with inspection straightedges or prisms
- Topping up the oil in the oil bath of the gearbox and feed boxes is carried out in accordance with the technical operating rules
- Topping up the lubricating oil of the ways is carried out as it is consumed, in accordance with the technical operating rules of the machine
- For preventive purposes, after treatment it is recommended to treat the ways once a year, for 200 hours, at a consumption rate of 6.0 ml per liter of the machine's own oil
Points to watch
- Only serviceable mechanisms having no parts with 100% wear and no mechanical damage are subject to treatment
- The mixture is added to the spindle oil bath and to the machine's lubrication system with the machine switched off
- Heat the oil by any safe method
- Before treating the hydraulic system, working fluid leaks must be eliminated
- After adding the composition to the hydraulic system, operate for the first 1-2 hours at a pressure load of up to 50% of the maximum permissible, and only then switch to rated load
- If the working surface of the ways is damaged deeper than 0.1 mm, the defects must first be eliminated by machining
- XADO revitalizants have no effect whatsoever on the operation of friction clutches running in the oil bath of gearboxes
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 46–50.