BRONZE BUSHING ANALYSIS WHY EXCEL IS YOUR BEST CHOICE FOR REPLACEMENT COMPONENTS INNER ECCENTRIC BUSHING SYMONS 5 1 / 2 FT CRUSHER PART#

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Kevin Spencer
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1 BRONZE BUSHING ANALYSIS WHY EXCEL IS YOUR BEST CHOICE FOR REPLACEMENT COMPONENTS INNER ECCENTRIC BUSHING SYMONS 5 1 / 2 FT CRUSHER PART#

2 BLIND SELECTION ENSURING A FAIR, SCIENTIFIC PROCESS COMPETITOR BUSHING EXCEL BUSHING Competitor bushing was purchased at random, just as a normal customer would Excel bushing was selected from inventory at random, just like a normal sale

3 PACKAGING COMPETITOR Low tip-over protection with only a 24 base Lower quality wood No corrosion resistance Not stackable 24

4 PACKAGING EXCEL Superior tip-over protection with a 48 base Superior protection against rough handling or stacking issues Superior corrosion resistance using foam and vapor barriers Superior storage reliability ensures part is ready when it s needed 48

5 PACKAGING EXCEL Component is covered in corrosion preventative Component is blocked and strapped to shipping palette

6 PACKAGING EXCEL Framed plywood box is built around the component Vapor barriers and expanding foam ensure the component is secure and protected Superior storage reliability ensures part is ready when it s needed

7 WORKMANSHIP COMPETITOR Evidence of numerous surface flaws from both machining and handling Some flaws are merely cosmetic, while others present real, functional challenges

8 WORKMANSHIP COMPETITOR Evidence of numerous surface flaws from both machining and handling Some flaws are merely cosmetic, while others present real, functional challenges

9 WORKMANSHIP COMPETITOR Evidence of numerous surface flaws from both machining and handling Some flaws are merely cosmetic, while others present real, functional challenges

10 WORKMANSHIP EXCEL Easier to work with Visually superior surface finish Superior reliability during installation

11 WORKMANSHIP EXCEL Easier to work with Visually superior surface finish Superior reliability during installation

12 LOCK-IN POCKETS SIDE-BY-SIDE COMPARISON COMPETITOR BUSHING EXCEL BUSHING

13 LOCK-IN POCKETS COMPETITOR Uses as-cast pockets Vary in depth and placement Don t line up accurately with mating piece Over 1 in misalignment

14 LOCK-IN POCKETS COMPETITOR Uses as-cast pockets Vary in depth and placement Don t line up accurately with mating piece Over 1 in misalignment

15 LOCK-IN POCKETS EXCEL Uses fully-machined pockets Uniform depth Correct placement to ensure proper correspondence to the eccentric Easier to install Will lock in place properly and reliably

16 LOCK-IN POCKETS EXCEL Uses fully-machined pockets Uniform depth Correct placement to ensure proper correspondence to the eccentric Easier to install Will lock in place properly and reliably

17 LOCK-IN POCKETS EXCEL Uses fully-machined pockets Uniform depth Correct placement to ensure proper correspondence to the eccentric Easier to install Will lock in place properly and reliably

BUSHING CHEMISTRY SAMPLES CUT AND SUBMITTED FOR TESTING Two independent labs were used to analyze cut samples Lead percentage was similar between Competitor

18 BUSHING CHEMISTRY SAMPLES CUT AND SUBMITTED FOR TESTING Two independent labs were used to analyze cut samples Lead percentage was similar between Competitor and Excel samples Excel sample featured much better lead distribution Competitor sample featured tin and zinc levels out of UNS 938 spec, hence yellow appearance

19 BUSHING CHEMISTRY INDEPENDENT LAB #01 C93800 SPEC. ELEMENT LIMITS (ASTM B584) COMPETITOR EXCEL Copper Tin Lead Zinc max Iron max Antimony max Nickel max Phosphorous max Sulfur max Aluminum max Manganese Silicon max

20 BUSHING CHEMISTRY INDEPENDENT LAB #02 C93800 SPEC. ELEMENT LIMITS (ASTM B584) COMPETITOR EXCEL Copper Tin Lead Zinc max Iron max Antimony max Nickel max Phosphorous max Sulfur max Aluminum max Manganese Silicon max

21 GRAIN SIZE SIDE-BY-SIDE COMPARISON COMPETITOR EXCEL

22 GRAIN SIZE COMPETITOR Competitor sample features much coarser grains Coarser grains could be resultant of slow cooling rates Coarse grains degrade important mechanical properties

23 GRAIN SIZE EXCEL Excel sample features much finer grains Fine grains controlled by cooling rates Fine grains provide higher and more uniform mechanical properties

24 LEAD DISTRIBUTION SIDE-BY-SIDE COMPARISON COMPETITOR FLSMIDTH USA INC. EXCEL

25 LEAD DISTRIBUTION COMPETITOR Both samples featured similar lead content percentage Competitor sample features much coarser lead distribution Coarse lead distribution threatens lubricity and protection against burn-up

26 LEAD DISTRIBUTION EXCEL Both samples featured similar lead content percentage Excel sample featured much finer lead distribution Among other key aspects, finer lead distribution increases reliability Excel sample would provide far better lubricity and protection against burn-up

27 MECHANICAL ANALYSIS Independent laboratory performed mechanical testing Excel sample showed significantly higher strength and ductility

28 MECHANICAL ANALYSIS Independent laboratory performed mechanical testing Excel sample showed significantly higher strength and ductility

MECHANICAL ANALYSIS SAMPLE TENSILE (ksi) YIELD (ksi) ELONGATION (%) Excel Pocket End 26.0 15.4 12.0 Excel Pocket End 26.8 17.0 12.0 Excel Taper End 27.9 16.9 11.0 Excel Taper End 26.8 18.3 8.

29 MECHANICAL ANALYSIS SAMPLE TENSILE (ksi) YIELD (ksi) ELONGATION (%) Excel Pocket End Excel Pocket End Excel Taper End Excel Taper End AVERAGE Comp. Pocket End Comp. Pocket End Comp. Taper End Comp. Taper End AVERAGE Stronger, more ductile bronze = Higher reliability under real-world conditions

30 MACHINING QUALITY COORDINATE MEASURING ANALYSIS Testing performed by CMM and with physical fit test into eccentric Excel sample features truer taper shape and concentric accuracy Excel sample has greater circular accuracy

31 MACHINING QUALITY COMPETITOR CMM RESULTS Competitor sample had errors in concentricity from OD to ID and across two different OD taper fits

32 MACHINING QUALITY EXCEL CMM RESULTS Excel sample features truer taper shape and concentric accuracy Excel sample has greater circularity accuracy

33 MACHINING QUALITY COMPETITOR FIT TEST Both samples were dry-fit into an eccentric to prove out CMM results Competitor sample had.006 gaps with feeler gauge top and bottom

34 MACHINING QUALITY EXCEL FIT TEST Excel sample had.002 gaps with feeler gauge top and bottom Excel bearing surface will interact far better with shaft Better interaction means better loading and heat transfer into eccentric while resistant to burn-ups and breakages

35 SURFACE FINISH SIDE-BY-SIDE COMPARISON at 2mm COMPETITOR EXCEL

SURFACE FINISH COMPETITOR VIEW at 2mm Competitor sample features a rougher roughness average Ra (190 min) Competitor sample features a double wave form, resulting in far

36 SURFACE FINISH COMPETITOR VIEW at 2mm Competitor sample features a rougher roughness average Ra (190 min) Competitor sample features a double wave form, resulting in far less contact area Less contact results in more surface pressure at the microscopic level More surface pressure increases susceptibility to burn-outs and break-in problems

37 SURFACE FINISH COMPETITOR VIEW at 100µm Competitor sample includes break-out chips at the microscopic level

38 SURFACE FINISH EXCEL VIEW at 2mm Excel sample features smoother roughness average Ra Excel sample features far more uniform surface shape Excel sample increases surface contact, spreading bushing load out over the surface Lower surface pressure aids break-in and lowers risk of burnout

EXCEL SURFACE FINISH EXCEL vs. COMPETITOR VALUE EXCEL COMPETITOR Ra 123.79 µin 190.09 µin Rq 146.05 µin 230.98 µin COMPETITOR Rz 726.18 µin 1307.

39 EXCEL SURFACE FINISH EXCEL vs. COMPETITOR VALUE EXCEL COMPETITOR Ra µin µin Rq µin µin COMPETITOR Rz µin µin Ra: Roughness Arithmetic Average of Absolute Values Rq: Roughness Root Mean Squared Rz: Avg. Distance Between 5 Highest Peaks & Lowest Valleys

Excel Foundry & Machine, has no affiliation with the OEM.

40 For More Information: Dan Wegner - Dan@ExcelFoundry.com All brand names, model names or marks are owned by their respective manufacturers. Excel Foundry & Machine, has no affiliation with the OEM. These terms are used for identification purposes only and are not intended to indicate affiliation with or approval by the OEM. All parts are manufactured by, for and warranted by Excel Foundry & Machine, and are not manufactured by, purchased from or warranted by the original equipment manufacturer.

REVIEW OF MICROSTRUCTURE AND PROPERTIES OF NON- FERROUS ALLOYS FOR WORM GEAR APPLICATION & ADVANTAGES OF CENTRIFUGALLY CAST GEARS

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