MANUFACTURE AND REPAIR OF SHAFTS FOR

ZSK 83/700 SCREW CONVEYOR MACHINES

V.I. Shlykov, K.V. Grachev, UDC 6 2 1 . 9 2 6 . 7 6 - 2 3 3 . 1 . 0 0 2 . 2

P.A. Vorontsov, and I.V. Degtyarev

P a r t s of ZSK 8 3 / 7 0 0 s c r e w c o n v e y o r m a c h i n e s , m a d e b y W e r n e r and P f l e i d e r e r , the m a i n s h a f t s of

which t r a n s m i t the t u r n i n g m o m e n t to the s c r e w c o n v e y o r b o x e s and m i x i n g w h e e l s and a l s o take up the
whole a x i a l load d u r i n g the e x t r u s i o n of p o l y e t h y l e n e , a r e the m o s t c o m p l i c a t e d and l e a s t w e a r - r e s i s t a n t
a n d u s e d f o r the g r a n u l a t i o n of p o l y e t h y l e n e .
One of the m a i n c a u s e s of the b r e a k d o w n of the m a i n s h a f t s is the w e a r of t h e i r s u p p o r t i n g j o u r n a l s at
the p o i n t s of the n e e d l e b e a r i n g s (Fig. 1). B r a n d e d s h a f t s have a s e r v i c e life f r o m 10,000 to 18,000 h. The
c h e m i c a l w o r k s of the Soviet Union do n o t r e c e i v e s p a r e s h a f t s for g r a n u l a t o r s (in five y e a r s the G r o z n y i
C h e m i c a l Group of E n t e r p r i s e s r e c e i v e d only four s h a f t s ) . T h e r e f o r e , the c h e m i c a l w o r k s a r e f o r c e d to
r e s t o r e t h e shafts w h i c h b r e a k down.
T h e r e s t o r a t i o n of shafts c o n s i s t s in p u t t i n g b e a r i n g r a c e s on the s u p p o r t i n g j o u r n a l s . M o r e o v e r , in
the f i t t i n g z o n e s the s h a f t s a r e gound 5 m m on e a c h s i d e . T h i s c o n s i d e r a b l y r e d u c e s the s t r e n g t h of the
s h a f t as a whole. The b e a r i n g r a c e s i m p r o v e the w e a r r e s i s t a n c e of the shafts by 9 000-12,000 h. However,
a f t e r the b e a r i n g r a c e s have b e e n m o u n t e d , the s h a f t s b r e a k in the w e a k e n e d z o n e s .

I" 163 ~ I Z O - - ~ ' t ' * --Z35-- =i

F i g . 1. Layout of the m a i n shaft b e a r i n g s in g r a n u l a t o r s :

1), 2) u p p e r and l o w e r shaft, r e s p e c t i v e l y ; 3) n e e d l e b e a r -
ings ; 4) s t u f f i n g box.

T A B L E 1. S u r f a c i n g C o n d i t i o n s
Diameter of the powdered-metal wire, in mm . . . . . . . . . . 2.3
Voltage, in V:
during idle motion . . . . . . . . . . . . . . . . . . . . . . . . . . 24
working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Current, in A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170-180
Numberof revolutions of the part per rain . . . . . . . . . . . . . 2.75
Rate of supply of wire, in m/h . . . . . . . . . . . . . . . . . . . . . 92
Pitch of surfacing, in mm . . . . . . . . . . . . . . . . . . . . . . . 3.5
Protrusion of electrodes, in turn . . . . . . . . . . . . . . . . . . . . 15-18
Thickness of surfacing on each side, in mm . . . . . . . . . . . . 3.0-3.2
Excess CO2 pressure at the outlet, in atm . . . . . . . . . . . . . . 0.3-0.4

T r a n s l a t e d f r o m K h i m i c h e s k o e i Neftyanoe M a s h i n o s t r o e n i e , No. 2, p p . 4 3 - 4 5 , F e b r u a r y , 1968.

171
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7 M:,Or ~ . . ~

Fig. 2 Fig. 3
:Fig. 2. D i a g r a m f o r b u i l d i n g - u p w e a r - r e s i s t a n t m a t e r i a l on s u p p o r t i n g j o u r n a l of shafts: 1) shaft;
2) pipe f o r s u p p l y of cooling liquid; 3) r e s t ; 4) stopping ring; 5) s u r f a c i n g p l a c e s ; 6) s t o p p e r ; 7)
chuck; 8) e l e c t r i c gas b u r n e r .
F i g . 3. G e n e r a l view of the b u i l t - u p shaft j o u r n a l .

In this connection, the G r o z n y i C h e m i c a l Group of E n t e r p r i s e s has adopted the m a n u f a c t u r e of new

g r a n u l a t o r shafts m a d e of 38KhN3MA s t e e l . The shafts of a length of 2223 m m have a c e n t r a l hole, 20 m m
in diam, f o r cooling. The b i l l e t is m a c h i n e d in a t h r e a d - c u t t i n g lathe, the c e n t e r d i s t a n c e of which is 2800
ram. The c e n t r a l hole is d r i l l e d in the s a m e lathe. The shaft up to the pinion is put into a spindle and f a s t -
ened in a f o u r - j a w e d chuck; the second end of the shaft is s u p p o r t e d by m e a n s of a r e s t . D r i l l i n g is c a r r i e d
out with a s e t of d r i l l s of a length f r o m 400 to 1200 ram. This is m a d e p o s s i b l e owing to the e x t e n s i o n of the
a r b o r . A cooling liquid is supplied to the cutting zone by m e a n s of a 6 m m pipe mounted in the a r b o r . The
whole a r b o r is divided into s e c t i o n s of 10 m m for control and r e j e c t i o n of chips.
A f t e r m a c h i n i n g and d r i l l i n g , the shaft j o u r n a l s a r e s u b j e c t e d to induction hardening. Then the shaft
is m a c h i n e d to n o r m a l d i m e n s i o n s a c c o r d i n g to design. The shaft pinion is m i l l e d in a s l i g h t l y m o d i f i e d
type 532 g e a r m i l l i n g machine. The shafts m a n u f a c t u r e d at the C h e m i c a l Group of E n t e r p r i s e s have a s e r -
vice life of 5000-6000 h. The p r o d u c t i o n cost of the shaft is 147 r u b l e s , w h e r e a s the cost of the shaft m a d e
by W e r n e r and P f l e i d e r e r is 1206 r u b l e s and 82 kopecks.
To i m p r o v e the w e a r r e s i s t a n c e of the m a i n shafts for g r a n u l a t o r s , the G r o z n y i Oil Institute in co-
o p e r a t i o n with the C h e m i c a l Group of E n t e r p r i s e s have developed and adopted techniques of m e c h a n i z e d
b u i l d i n g - u p of w e a r - r e s i s t a n t m a t e r i a l on s u p p o r t i n g j o u r n a l s . F o r this, a s u r f a c i n g machine was used.
This m a c h i n e c o n s i s t s of a r o t a t o r (DIP-300 lathe) and a P S h - 5 - 1 s e m i a u t o m a t i c w e l d e r ( r e - e q u i p p e d for
s u r f a c i n g in an a t m o s p h e r e of c a r b o n dioxide) which was mounted on the s u p p o r t of the lathe.
The s u r f a c i n g s c h e m e is shown in F i g . 2. The shaft is fixed n e a r the mounted s u p p o r t i n g j o u r n a l s ,
on one side in the chuck, and on the other side, in the r e s t . Such a fixing method e n s u r e s m i n i m u m d e f o r m a -
tion of the shaft, during s u r f a c i n g . I n t e r n a l w a t e r cooling along the c e n t r a l hole in the shaft a l s o helps to
r e d u c e the d e f o r m a t i o n .
The p r e p a r a t i o n to s u r f a c i n g c o n s i s t s in g r i n d i n g of the j o u r n a l s , 1 m m on e a c h s i d e , at a d i s t a n c e
of 8-10 m m f r o m the pinion. The p u r p o s e of this is to r e d u c e the s t r e s s c o n c e n t r a t i o n in the zone of t r a n s i -
tion f r o m the j o u r n a l to the pinion. The s u r f a c i n g was s t a r t e d f r o m the 2 0 - 3 0 - r a m - w i d e stopping rings
which w e r e cut off a f t e r the final m a c h i n i n g o p e r a t i o n . The use of stopping r i n g s m a k e s it p o s s i b l e to r e d u c e
the i n t e r n a l s t r e s s e s in the j o u r n a l of the shaft, which a r e p r o d u c e d at the beginning of the s u r f a c i n g o p e r -
ation, and to p r e s e r v e the r e q u i r e d d i m e n s i o n s and shape of the b e a r i n g s u r f a c e .
The w e a r - r e s i s t a n t m e t a l can be b u i l t - u p on the j o u r n a l of shafts with type Kh12M p o w d e r e d - m e t a l
w i r e in an a t m o s p h e r e of CO 2 in one p a s s . The w i r e has a r e d u c e d content of c a r b o n (0.6-0.7%) to r e d u c e
the p o s s i b i l i t y of c r a c k initiation in the b u i l t - u p m e t a l .
The g e n e r a l view of the shaft j o u r n a l is shown in F i g . 3. The b u i l t - u p j o u r n a l s a r e p r e m a c h i n e d in a
lathe with a cutting tool with a VK8 p l a t e . The longitudinal supply is 0.15 m m / r e v , and the r o t a t i o n a l s p e e d
of the shaft is 25 r p m . A f t e r m a c h i n i n g the s u r f a c e d a r e a s a r e ground.

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 TABLE 2
Expenses cal- Service life
Manufactur -
Service life, culated for 1 h per 1 ruble
Shaft ing cost, in
in h of service of expenses,
rubles
life, in rubles in h

Made by Werner and

Pfleiderer 1206.82 18.000 0.070 15
Re-equipped with bearing
races 70.00 I0.000 0.007 143
Induction hardened 147.00 6.000 0.025 40
Restored by surfacing after
re-equipment with bear-
ing races and induction
hardening 50.00 5.000 0.001 I00
New, surfaced 200.00 20.000 0.010 I00

F i g . 4. M i c r o s t r u c t u r e of the b u i l t -
up m e t a l of type K h l 2 M p o w d e r e d -
m e t a l w i r e in an a t m o s p h e r e of CO 2.
E t c h i n g in a s o l u t i o n of t h r e e p a r t s
of ttC1 in one p a r t of HNO 3. M a g n i -
f i c a t i o n x 200.

T h e h a r d n e s s of the b u i l t - u p s u r f a c e is H R C - 5 6 - 5 8 . The f i n i s h a f t e r g r i n d i n g f u l l y s a t i s f i e s the

r e q u i r e m e n t s of s u r f a c e s on w h i c h n e e d l e b e a r i n g s a r e u s e d . T h e c h e m i c a l c o m p o s i t i o n of the b u i l t - u p
m e t a l i s : 0.6-0.7%C, 0.8-1.0% Mn, 0.75-0.85% Si; 11.5-12.0% C r ; 0.25-0.35% T i ; and 0.9-1.1% Mo. The
m i c r o s t r u c t u r e of the b u i l t - u p m e t a l is shown in F i g . 4.
T h e w e a r of the s h a f t s w h i c h had b e e n r e s t o r e d b y s u r f a c i n g and o p e r a t e d f o r 10,000-12,000 h w a s
0 . 0 2 - 0 . 0 4 m m on e a c h s i d e (the t o l e r a b l e w e a r is 0.1 r a m ) . T h u s , a c c o r d i n g to c a l c u l a t i o n s , the s h a f t s
w i t h s u r f a c e d j o u r n a l s s h o u l d w o r k m o r e than 18,000-20,000 h. T h i s s e r v i c e l i f e is l o n g e r t h a n the s e r v i c e
l i f e of s h a f t s m a d e b y W e r n e r and P f l e i d e r e r .
T h e h i g h w e a r r e s i s t a n c e of s h a f t s w i t h s u r f a c e d j o u r n a l s , p a r t i c u l a r l y in c o m p a r i s o n w i t h the w e a r
r e s i s t a n c e of i n d u c t i o n h a r d e n e d s h a f t s , c a n b e e x p l a i n e d b y the s t r u c t u r e of the m e t a l w h i c h is c h a r a c -
t e r i s t i c f o r h i g h - c h r o m i u m c a s t a l l o y s . By s t u d y i n g w o r n i n d u c t i o n h a r d e n e d s h a f t s it w a s e s t a b l i s h e d t h a t
the w e a r m e c h a n i s m c o r r e s p o n d s to the s u c c e s s i v e a b r a s i v e w e a r , p r o b a b l y , b y a b r a s i v e p r o d u c t s . T h e r e
a r e t r a c e s of w o r k h a r d e n i n g on the s h a f t s with s u r f a c e d j o u r n a l s , b u t w i t h o u t v i s i b l e m a r k s w h i c h a r e
characteristic for abrasive wear.
T a k i n g into a c c o u n t the s e r v i c e life and the c o s t of o p e r a t e d g r a n u l a t o r s h a f t s , a s i m p l i f i e d c a l c u l a -
t i o n of the e c o n o m i c s c a n b e m a d e a f t e r the t e c h n o l o g i c a l o p e r a t i o n s d e s c r i b e d a b o v e (see T a b l e 2).
T h e a n a l y z e d r e s u l t s of s i m p l i f i e d c a l c u l a t i o n of the e c o n o m i c s , c o n n e c t e d w i t h the m a n u f a c t u r e and
o p e r a t i o n of d i f f e r e n t s h a f t s , s h o w e d t h a t the e x p e n s e s w e r e l o w e s t f o r s h a f t s w h i c h had b e e n r e - e q u i p p e d
w i t h b e a r i n g r a c e s and r e s t o r e d a f t e r p u t t i n g on the b e a r i n g r a c e s and a f t e r i n d u c t i o n h a r d e n i n g . H o w e v e r ,
t h e s e s h a f t s b r e a k down a s a r e s u l t of b r e a k a g e in the zone w e a k e n e d b y g r o o v i n g . T h i s c a u s e s f r e q u e n t
s t o p p a g e s f o r r e p a i r s , and m a k e s the o p e r a t i o n s v e r y e x p e n s i v e .
T h u s , it is a d v i s a b l e to s u r f a c e s h a f t s , p a r t i c u l a r l y the new o n e s , s i n c e t h i s c a n b e done r e p e a t e d l y .

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