Forging hammers, presses and dies
The units subject to treatment are those of forging hammers, presses and dies: the compressor of the pneumatic hammer, the hydraulic system of hydraulic hammers and presses, the main-motion cylinder and the guideways. The purpose is to restore working surfaces and protect them against further wear under normal operating conditions.
Procedure for treating forging hammers, presses and dies with XADO revitalizant gel
What is treated
- Serviceable units of forging hammers, presses and dies that have no parts with limit wear or mechanical damage.
- Compressor of the pneumatic hammer.
- Hydraulic system of hydraulic hammers and presses.
- Main-motion cylinder of hammers.
- Guideways of hammers, presses and dies.
- Guideways free of 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 container).
- Treatment of piston compressors is recommended to be carried out with relatively clean oil (residual oil service life not less than 40%).
When treatment is not performed
- Units having parts with limit 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 to carry out the treatment.
- In the case of significant (or close to limit) wear of the working surface of the main-motion cylinder, or of damage deeper than 0.1 mm, it is recommended, before the main treatment, to carry out an additional treatment of the cylinder surface by applying a thin layer of "XADO revitalizant gel for cylinder restoration".
- After the compressor is switched on, it must operate in normal mode without overloads.
Preparation
- Before starting the treatment of the compressor, flush or replace the filter elements in the compressor lubrication system and eliminate oil leaks.
- Before starting the treatment of the hydraulic system with XADO revitalizant, eliminate working fluid leaks.
- 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.
- Dissolving the gel: pour a small amount of the standard oil (working fluid) into a separate vessel (container) at a ratio of 1 part of the gel being dissolved to 5 - 10 parts of oil heated to 40 - 60 °C; mix the composition thoroughly until a homogeneous mixture is obtained.
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Compressor vibration level (vibration acceleration, vibration velocity, vibration displacement) at fixed points in the vertical, horizontal and axial directions | vibrometer | before the start of treatment and after completion of the full cycle |
| Power consumption (or current consumption) of the electric motor with the compressor unloaded | electricity meters, current clamps, wattmeter or multi-purpose instrument | before the start of treatment and after completion of the full cycle; with the compressor unloaded |
| Oil pressure in the compressor | standard pressure gauge | at a fixed operating temperature; before the start of treatment and after completion of the full cycle |
| 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 thermometer, infrared pyrometer or other standard temperature measuring instrument | 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 |
| Vibration level of the hydraulic machine | vibrometer | at specified points under fixed operating modes of the hydraulic system |
| Flatness and straightness of the guideways | special inspection straightedges or prisms | before and after treatment, if necessary; with periodic manual lubrication — before the start of treatment and after completion of the full cycle |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| XADO revitalizant gel for compressors and bearings (industrial) | 1.5 ml per 1.0 l of standard oil for one treatment stage | crankcase of the pneumatic hammer compressor; 3 stages without oil change |
| XADO revitalizant gel for power steering (industrial) | 0.6 ml of gel per 1 litre of working fluid for one treatment stage | hydraulic system working fluid tank; 6 stages without oil change, for new hydraulic systems or those with wear up to 10% — 4 stages |
| XADO revitalizant gel for compressors and bearings (industrial) | 1.5 ml of gel per 1 litre of lubricating oil for one treatment stage | lubrication system of the cylinder-piston group of the hammer's main-motion cylinder; 3 stages, for new cylinders or those with wear up to 10% two stages are sufficient |
| XADO revitalizant gel for compressors and bearings (industrial) | 9.0 ml per 1 litre of standard oil for the entire treatment cycle | oil bath of guideways with a centralized circulating oil lubrication system |
| XADO revitalizant gel for compressors and bearings (industrial) | 9.0 ml per 1 litre of oil | dissolving in the lubricating oil for guideways lubricated with oil periodically (from a separate container) |
| XADO revitalizant gel (preventive treatment of guideways) | 6.0 ml per one litre of standard oil | once a year, over 200 hours of operation — to increase service life after treatment, as well as in new machines or those with insignificant guideway wear (up to 10%) |
| XADO revitalizant gel for cylinder restoration | a thin uniform layer on the working surface of the cylinder | additional treatment in case of significant wear or damage deeper than 0.1 mm, before the main treatment |
| Standard oil (working fluid) for dissolving the gel | 1 part of the gel being dissolved to 5 - 10 parts of oil heated to 40 - 60 °C | for all units covered by the procedure |
Treatment stages
- Pneumatic hammer compressor, first stage: prepare "XADO revitalizant gel for compressors and bearings (industrial)" at a rate of 1.5 ml per 1.0 l of standard oil; dissolve it in standard oil heated to 40 - 60 °C (1 part of gel to 5 - 10 parts of oil), mix thoroughly until a homogeneous mixture is obtained and introduce it into the compressor crankcase; switch on the compressor and operate in normal mode without overloads.interval before the next stage — 8-12 hours of total compressor operation
- Pneumatic hammer compressor, second stage — as for the first stage.at an interval of 8-12 hours of total compressor operation
- Pneumatic hammer compressor, third stage — as for the first stage. Treatment of the compressor is considered complete after 450 hours of compressor operating time, counted from the start of the first treatment stage.450 hours of compressor operating time from the start of the first stage
- Hydraulic system, first stage: prepare "XADO revitalizant gel for power steering" at a rate of 0.6 ml of gel per 1 litre of working fluid; pour the 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, mix thoroughly until a homogeneous mixture is obtained and introduce it into the working fluid tank; switch on the hydraulic system, provide a pressure load of up to 50% of the maximum permissible and operate for 1 - 2 hours, then continue operation at rated load in normal mode.1 - 2 hours at a load of up to 50% of the maximum permissible, then normal mode; interval before the next stage — 8-12 hours of total hydraulic system operation
- Hydraulic system, second stage — as for the first stage, at the normal load of the hydraulic drive.at an interval of 8-12 hours of total hydraulic system operation
- Hydraulic system, third stage — as for the first stage, at the normal load of the hydraulic drive.at an interval of 8-12 hours of total hydraulic system operation
- Hydraulic system, fourth stage — as for the first stage, at the normal load of the hydraulic drive.at an interval of 8-12 hours of total hydraulic system operation
- Hydraulic system, fifth stage — as for the first stage, at the normal load of the hydraulic drive.at an interval of 8-12 hours of total hydraulic system operation
- Hydraulic system, sixth stage — as for the first stage, at the normal load of the hydraulic drive. Treatment of new hydraulic systems or those with wear up to 10% is carried out according to the above procedure in 4 stages.the full treatment cycle of the hydraulic system is 550 hours of total operating time
- Hammer main-motion cylinder, first stage: take a small amount of oil heated to 40 - 60 °C into a separate vessel (1 part of the gel being introduced to 5 - 10 parts of oil), add the calculated amount of "XADO revitalizant gel for compressors and bearings" (1.5 ml of gel per 1 litre of standard oil), mix thoroughly until a homogeneous mixture is obtained; with the unit not running, introduce the prepared mixture into the hammer lubrication system; switch on the hammer and ensure operation in normal mode.total operation for 8 - 12 hours in normal mode
- Hammer main-motion cylinder, second stage — as for the first stage.at an interval of 8 - 12 hours of total hammer operating time under normal operating conditions
- Hammer main-motion cylinder, third stage — as for the first stage. The treatment is considered complete after 450 hours of total hammer operating time from the start of the first stage. For new main-motion cylinders or those with insignificant (up to 10%) wear, two treatment stages are sufficient.450 hours of total hammer operating time from the start of the first stage
- Additional treatment of the working surface of the main-motion cylinder (in case of significant wear or damage deeper than 0.1 mm): partially disassemble the cylinder to provide access to the working surface; wash the cylinder surface free of contamination and wipe it dry; apply XADO revitalizant gel in a thin uniform layer to the working surface by any available means; assemble the cylinder and provide reciprocating motion of the piston in idle mode; put the unit into operation and run it in normal mode, additionally treating it through the lubrication system with "XADO revitalizant gel for compressors and bearings (industrial)" in 3 stages.reciprocating motion of the piston for 20-30 min at idle; then operation in normal mode for not less than 450 hours
- Guideways with a centralized circulating oil lubrication system: after visual inspection of the friction surfaces and measurements of flatness and straightness, introduce into the oil bath the required amount of "XADO revitalizant gel for compressors and bearings (industrial)" at a rate of 9.0 ml per 1 litre of standard oil for the entire treatment cycle, start the machine and operate it in normal mode.the full treatment cycle of the guideways is not less than 550 hours of total machine operating time
- Guideways with periodic manual oil lubrication: after visual inspection of the friction surfaces and measurements of flatness and straightness, dissolve "XADO revitalizant gel for compressors and bearings (industrial)" in the lubricating oil at a rate of 9.0 ml per 1 litre of oil, lubricate the guideways with the resulting composition and start the hammer in normal operating mode; periodic lubrication of the guideways throughout the treatment cycle is carried out at least twice per shift or once every 4 hours of machine operation.the full treatment cycle of the guideways is not less than 700 hours of total machine operating time
After treatment
- After completion of the full treatment cycle of the compressor, re-measure the vibration level, the power consumption (current) of the electric motor with the compressor unloaded, and the oil pressure at a fixed operating temperature.
- After completion of the full treatment cycle of the hydraulic system, re-measure the pressure in the hydraulic system, the operating temperature of the working fluid, the output (delivery) of the hydraulic pumps and the vibration level of the hydraulic machine.
- After treatment of the guideways, if necessary, take measurements of flatness and straightness with special inspection straightedges or prisms.
- For preventive purposes, to increase service life during further operation after treatment with XADO revitalizants, as well as in new machines or those with insignificant guideway wear (up to 10%), 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 standard oil.
- Lubricating oil is topped up as it is consumed, in accordance with the machine's technical operating rules.
Points to watch
- Only serviceable units of forging hammers, presses and dies that have no parts with limit wear or mechanical damage are subject to treatment.
- Treatment of piston compressors is recommended to be carried out with relatively clean oil (residual oil service life not less than 40%).
- After the composition has been introduced, the compressor must operate in normal mode without overloads.
- At the first stage of treating the hydraulic system, the pressure load must not exceed 50% of the maximum permissible for 1 - 2 hours.
- The prepared mixture is introduced into the hammer lubrication system with the unit not running.
- Damage to the working surface of the guideways deeper than 0.1 mm must be eliminated by machining (planing, grinding) before treatment using XADO technology.
- Treatment of guideways with XADO revitalizant compositions makes it possible to replace one of the types of finishing treatment of guideways — 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.
- Revitalizant gel for cylinder restorationEngine cylinders with heavy wear or surface damage deeper than 0.15 mm — applied to the bore before the main treatment.
Source: Instructions for the use of XADO revitalizant gels IE-24.6-25612000-005-2008, pages 50–53.