The
equipment of industrial enterprises is mostly large-scale equipment. In
the production and operation, due to various factors such as inadequate
installation, untimely maintenance and insufficient lubrication, the
shaft head is often damaged, and the bearing seat (bearing hole) wear
phenomenon often occurs. The bearing hole refers to the joint between the outer diameter of the
bearing and the bearing housing, which is usually called the bearing
chamber.
Bearing hole wear:
Bearing hole wear refers to the relative sliding of the rolling bearing with the matching hole. The fault phenomenon is that the bearing part has a high temperature and a large vibration. When you open it, there is a slip on the inner ring surface of the bearing housing, and even the groove surface is ground. From this situation it has been determined that the bearing hole is worn. The
negative impact of bearing hole wear on the equipment is very large,
which intensifies the wear of the matching parts, even the fee, damages
the equipment, reduces the precision of the machine, and increases the
friction force, converting a large amount of energy into useless heat
and noise, reducing The efficiency. Therefore, in this case, the maintenance should be arranged as soon as possible according to the actual situation.
Traditional repair method for bearing hole wear:
At
present, the common methods for repairing bearing hole wear in China
are inlaid bushings, pitting, surfacing, brush plating, thermal
spraying, laser cladding, etc. These repairing processes are emerging
while promoting technological process improvement and development. Complex
process conditions and on-site environments are limited, especially in
the face of equipment problems such as sudden emergencies, large
equipment, and complex disassembly. These processes are obviously more
than enough. The
way of bushing and pitting is a very old method of shaft repair, which
has poor repair effect and is rarely used at present. A brief analysis of other centralized repair methods is now available:
1. Surfacing (repair welding) process
Surfacing
is a welding process in which a layer of wear-resistant,
corrosion-resistant, heat-resistant metal is applied to the surface or
edge of the workpiece. Different
workpieces and surfacing electrodes should use different surfacing
processes to achieve satisfactory surfacing results. The most common problem encountered in surfacing is cracking. After general surfacing (welding), heat treatment is required and machined. The biggest disadvantage of repair welding is that the thermal stress
is concentrated, and the heat affected zone is large, which easily
causes the deformation of the shaft.
2, thermal spraying process
Thermal
spraying is a metal surface processing method in which a molten
material is sprayed onto a surface of a part by a high-speed air stream
to form a sprayed layer. Thermal spraying requires a professional spraying tool. The main
disadvantage of thermal spraying is that the bonding strength between
the spraying layer and the substrate technology is insufficient, and the
spraying layer has defects such as pores, which is difficult to
machine.
3, brush plating process
Brush plating is the process of obtaining a coating on the surface of a workpiece by electrolysis. The advantage is that online repair can be achieved, and its disadvantages are very obvious. The
brush plating coating of the brush plating process is limited by the
amount of wear, and the brush plating thickness of the general brush
plating coating is less than 0.2 mm. When the wear amount is more than 0.2mm, the brush plating efficiency
will be doubled, and when the brush plating layer is too thick, the
brush plating layer is easy to fall off during use, and the service life
is short.
4, laser cladding process
Laser cladding, also known as laser cladding or laser cladding, is a new surface modification technology. It
forms an additive cladding layer that is metallurgically bonded to the
surface of the substrate by adding a cladding material to the surface of
the substrate and using a high energy density laser beam to fuse it
with a thin layer of the substrate surface. The
advantage of laser cladding is that the heating of the substrate is not
affected by the metal matrix, and the deposited metal cools quickly. The disadvantage is that the construction period is long and the price
is expensive; the cladding layer still belongs to the electro-melting
pool, has large internal stress, is easy to be deformed, and has the
possibility of cracking.
Sole Industrial Carbon Nanopolymer Repair Technology:
Sole
carbon nano-polymer material is made up of advanced materials such as
carbon nanotubes and graphene. Various materials complement each other
in performance and produce synergistic effects, which makes the overall
performance of polymer materials better than the original materials. With
strong adhesion, mechanical properties, and chemical resistance, it is
widely used in metal equipment for mechanical wear, scratches, pits,
cracks, leaks, repair of sand holes, etc., as well as various chemical
storage tanks. Chemical corrosion protection and repair of reaction tanks and pipelines.
Sower Technology repairs bearing hole wear specifications and standards:
1. Remove the parts to be repaired and other related parts to ensure sufficient construction space;
2. Disassemble the bearing to expose the surface of the bearing
chamber to be repaired, and check the wear size to determine the amount
of material;
3.
Use acetylene flame to bake out the grease that penetrates into the
surface of the bearing chamber until there is no sparks. During the
baking process, control the metal temperature below 90 °C, and bake it
several times. (Prevent the deformation of the parts and improve the
bonding of the materials. performance)
4. According to the surface condition of the bearing chamber, the
surface of the worn part is polished with a power tool. The main purpose
is to remove the impurities and the oxide layer and clean it with
absolute ethanol; (the unheated reference surface should not be ground)
5. Clean the parts to be repaired and the corresponding parts with
acetone or absolute ethanol to ensure that the surface is clean and dry.
6. Apply SD7000 release agent to the outer ring of the bearing. Apply
evenly on both sides to ensure that there are no dead ends, dry
naturally or air dry;
7. Reconcile the SD7101H repair material in strict proportion to the
volume ratio of 2:1 until there is no color difference, and the blending
speed should be fast;
8. Apply polymer material. Apply
the blended material to the area to be repaired and repeatedly squeeze
with a putty knife or finger to ensure that the material is filled and
fully bonded. The
thickness of the application is slightly higher than the standard size,
and then the excess material is scraped off in one direction by a flat
ruler or a scraper depending on the reference plane of the bearing
chamber. As shown in FIG.
9. Curing. Naturally solidified (6 hours at ambient temperature 24 ° C) or heat
cured with iodine tungsten lamps (chandelier height 60 cm, 1 hour).
10. Surface grinding. The surface is sanded with 80 mesh sandpaper, the main purpose is to
remove the high point and roughen the surface of the repaired material.
11.
Reconcile the appropriate amount of material again, and apply a thin
material of about 20 wires on the basis of the first pass material (the
bearing chamber can be reserved for 3-5 mm on both sides), based on the
release bearing outer ring release agent. Also apply thinly to the material of about 20 wire thickness (the
bearing can be reserved for 3-5mm on both sides) and directly assemble
the bearing;
12.
Fast assembly speed (20-30 minutes when the ambient temperature is 24
°C). After the position is in place, remove the extruded repair material
with a scraper (to avoid material falling into the bearing raceway). Moving parts;
13.
Curing for sufficient time, the material is fully cured at 24 hours /
24 ° C, and the curing time is reduced by half for every 11 ° C increase
in temperature, but the elevated temperature must not exceed 100 ° C. (The temperature referred to above is the temperature of the material itself, not the ambient temperature). If the best performance is achieved, it is recommended to cure at 60-80 ° C for at least 2-4 hours. The curing time can be shortened by heating with iodine tungsten lamp
or hot air heater. Note that it is not possible to directly contact the
material with open flame, and do not let the material temperature and
the substrate temperature differ too much to avoid sudden rise and fall.
Sole carbon nano-polymer material repair bearing chamber wear case show:
The vertical grinding rocker bearing chamber wears on-site repair, bearing type 24168ca/w33, wear varies from 0.3 to 0.8mm. According to the wear of the equipment, the standard scraping method is used to repair the two times based on the non-wearing.
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