Industrial Shafts Rebuild and Maintenance Guide

Transcription

1 Industrial Shafts Rebuild and Maintenance Guide

2 2 LOCTITE Industrial Shafts Rebuild and Maintenance Guide Value-Added Partnership Our large, experienced team of engineers provide documented design and application support. Cost Savings and Reliability LOCTITE solutions are more cost effective compared to conventional mechanical methods. Global Leadership LOCTITE is the global technology leader with wide product range sold through an extensive sales and distributor network. Superior Product Performance LOCTITE adhesives and sealants are recognized as the best performing products in the industry. LOCTITE is the world s #1 brand of engineering adhesives & sealants End-User Training We provide professional training programs to customers that help them identify opportunities for improving process efficiency, quality and costs. Achieving more with less Our commitment to leadership in sustainability is deeply embedded in our values. With our revised Sustainability Strategy for 2030, we are building on our strong track record. At the same time, we are aiming to address one of the central future challenges: to decouple growth from resource consumption. At the heart of this strategy is therefore the simple, yet challenging, ambition: to achieve more with less. It aims to create more value for our customers, consumers, communities and the company alike, while simultaneously reducing the environmental footprint.

3 LOCTITE Industrial Shafts Rebuild and Maintenance Guide 3 CONTENT SHAFT APPLICATION DIAGRAM 4 SHAFT REPAIR AND MAINTENANCE Shaft Repair Solution Securing Cylindrical and Taper Joints Keyed Assemblies Spline Assemblies 6 SHAFT REPAIR PRODUCT SELECTOR CHART 14

4 4 LOCTITE Industrial Shafts Rebuild and Maintenance Guide Shaft Application Diagram 1 Secure Fixed Spline Assemblies LOCTITE Rebuild Worn Shafts LOCTITE EA 3478 Superior Metal 3 Prevent Keyway Wear LOCTITE 243 Threadlocker Stick LOCTITE 248 Threadlocker Stick 4 Repair Worn Keyways LOCTITE 660 LOCTITE EA 3478 Superior Metal 2 3 4

5 LOCTITE Industrial Shafts Rebuild and Maintenance Guide Lubricate and Protect Spline Assemblies LOCTITE LB 8012 Moly Paste 6 Sleeving a Worn Shaft LOCTITE Secure Cylindrical & Taper Joints LOCTITE s 5 Additional LOCTITE Products LOCTITE SF 7070 ODC-Free LOCTITE 7649 Primer 6 7

6 6 LOCTITE Industrial Shafts Rebuild and Maintenance Guide Shaft Repair Solution CHALLENGE Repairing a badly worn shaft CAUSES Out-of-tolerance machining results in loose components; this leads to micro-movement and wear Load produces axial forces that are higher than original calculations Insufficient interference or inappropriate loads lead to spun bearings Use of components in aggressive environments and at elevated operating temperatures SOLUTION #1 Rebuilding the damaged shaft with LOCTITE Superior Metal Using a lathe, undercut the shaft in the worn area as follows: Shaft diameter: 13 mm to 25 mm; desired undercut: 1.5 mm. Shaft diameter: 25 mm to 75 mm; desired undercut: 3 mm. Dovetail the ends of the worn area to anchor the application into place. Finish undercutting by machining a rough cut surface (e.g., Rz: = 100 µm). The larger the shaft diameter, the coarser the cut. Clean parts with LOCTITE ODC Free Cleaner & Degreaser. Apply a very thin layer of LOCTITE Superior Metal and force it into the rough surface finish. Turn the shaft at a very low speed and continue to apply adhesive using a putty knife or similar tool. Build the surface above the final desired level. Allow the adhesive to cure for 12 hours at room temperature. If necessary, apply dry heat to the repair area to speed the cure. Machine the repair to the required dimensions. Cut the material when the component is dry, using carbide or high speed steel. If polishing is required, use an abrasive paper. BENEFITS Prevent downtime and scrap costs by reparing worn shaft Epoxy solution uses standard machine tools, no special equipment or training required

7 LOCTITE Industrial Shafts Rebuild and Maintenance Guide 7 SOLUTION #2 Sleeving reliably with LOCTITE s Determine appropriate size of sleeve. Create a transition fit joint between shaft and sleeve (for tapered joints, create a press fit). Ensure the outside diameter is the specified shaft diameter (for a taper joint, the outside diameter should be the nominal diameter of the original cone). Roughen the surface. Clean parts with LOCTITE ODC-Free Cleaner & Degreaser. Apply a bead of LOCTITE 648 to the circumference of the shaft at the leading edge of the component to be inserted. Apply the adhesive to both parts of the assembly. In the case of a shrink fit (using thermal energy for assembling), apply the adhesive onto the cold part, coating the complete engagement area. Assemble sleeve; in some cases, heat should be applied to the fit. Wipe off excess adhesive. Allow adhesive to cure. Follow the same procedure for press-fit joints between the sleeve and bearing. BENEFITS Repair worn shaft Unitize assembly, distributing load evenly Prevent downtime and scrap costs Protect new components against wear, abrasion and chemical attack

8 8 LOCTITE Industrial Shafts Rebuild and Maintenance Guide Securing Cylindrical and Taper Joints CHALLENGE Reliably secure components to shaft CAUSES Out-of-tolerance machining results in loose components, leading to micro-movement and wear Load produces axial forces that are higher than original calculations Insufficient interference or inappropriate loads lead to spun bearings Use of components in aggressive environments and at elevated operating temperatures SOLUTION Mount components to shaft using LOCTITE s Type of Fit LOCTITE Retaining Compound Benefit Maximum Repair Gap Cure Time (Setup/Full Strength) Press Fit LOCTITE 648 LOCTITE 668 LOCTITE 609 High Strength/ Rapid Cure Semisolid General Purpose up to 0.005" (0.1 mm) up to 0.005" (0.1 mm) up to 0.005" (0.1 mm) 5 minutes/24 hours 30 minutes/24 hours 10 minutes/24 hours Slip Fit LOCTITE 620 LOCTITE 680 High Temp High Strength up to 0.015" (0.4 mm) up to 0.015" (0.4 mm) 30 minutes/24 hours 10 minutes/24 hours Medium to Large Gaps LOCTITE 660 Restore Worn Parts up to 0.020" (0.5 mm) 20 minutes/24 hours Clean parts with LOCTITE ODC-Free Cleaner & Degreaser. Roughen the shaft-mounted component and shaft with abrasive paper at the bonding area. Re-clean parts. Apply a bead of repair adhesive to circumference of the shaft at leading edge of the component. Apply adhesive to both parts of assembly. In the case of a shrink fit (using thermal energy for assembling), apply adhesive onto the cold part, coating the entire engagement area. Assemble shaft-mounted component; in some cases, heat should be applied to the transition fit. Wipe off excess and allow to cure. BENEFITS Adhesive fills airspace - sealing from leaks, rust and corrosion Eliminates micro-movement between component and shaft Provides 100% contact, distributing loads and stress evenlyrequired

9 LOCTITE Industrial Shafts Rebuild and Maintenance Guide 9 CHALLENGE Prevent bearing spinout, corrosion and component damage CAUSES Bearings are prone to spinning either on their shafts or within their housings. This results in damage to these parts regardless of whether or not they are a press, shrink or slip fit The airspace that exists between a bearing and shaft is an area where rust can form and cause damage to the parts and can also be a leak path for fluids Airspace allows micro-movement leading to fretting and corrosion SOLUTION Retain joints using LOCTITE 609 General Purpose or LOCTITE 648 High Strength s Clean parts with LOCTITE ODC-Free Cleaner & Degreaser. Apply a bead of LOCTITE to the circumference of the shaft at the leading area of the component. Press the bearing onto the shaft using normal techniques. Wipe off excess material. BENEFITS Reduces shaft and/or bearing housing damaged Fills airspace - sealing from leaks, rust and corrosion Eliminates micro-movement between bearing and shaft that could lead to fretting damage Provides 100% contact, distributing loads and stress evenly

10 10 LOCTITE Industrial Shafts Rebuild and Maintenance Guide Keyed Assemblies CHALLENGE Preventing keyway wear CAUSES In a new assembly the fit between the key and keyway is usually tight; however, over time, wear can cause this fit to loosen, leading to damage to the keyway SOLUTION LOCTITE Medium Strength Threadlockers are appropriate for gap fill and will provide needed medium strength, while allowing easy removal for servicing Clean parts with LOCTITE ODC-Free Cleaner & Degreaser. Apply several drops of LOCTITE 243 Threadlocker into the keyway or apply LOCTITE 248 Threadlocker Stick to the key. Insert the key into the keyway. Wipe off excess adhesive. Allow to cure before assembling the shaft-mounted component. BENEFITS Eliminates micro-movements that can lead to fretting Prevents keyway wear Prevents corrosion Eases disassembly

11 LOCTITE Industrial Shafts Rebuild and Maintenance Guide 11 CHALLENGE Repairing worn keyed assemblies CAUSES Alternating loads and combined loading results in micro-movement wear and loose parts Over time, wear can cause keys to loosen, leading to damage of the keyway Out-of-tolerance machining SOLUTION #1 LOCTITE 660 is a very thick product, allowing it to fill large gaps Clean shaft, keyway and key stock with LOCTITE ODC-Free Cleaner & Degreaser. Apply LOCTITE 660 Retaining Compound into the worn keyway. Insert the key into the keyway, wipe off excess and allow to cure. Assemble component as usual. SOLUTION #2 Repairing badly worn keyed assemblies by resizing the existing keyway Resize the worn keyway. Select proper keystock to fit the new keyway. Machine a step in the new key to fit the female component. Clean parts with LOCTITE ODC-Free Cleaner & Degreaser. Apply LOCTITE 648 Retaining Compound to the keyway of the shaft (where there is a high power application, apply LOCTITE 648 onto the whole shaft at the engagement area). Assemble the key into the shaft. Wipe off excess adhesive. Allow product to cure. SOLUTION #3 For Badly Worn Keyway: fill in worn keyway and cut new keyway Clean parts with LOCTITE ODC-Free Cleaner & Degreaser. Apply LOCTITE Superior Metal into the keyway of both the shaft and collar. Fill all the available space. Allow to cure. If a rounded surface is required, machine the repair to the original dimensions of the shaft and bore of the collar. Machine a new keyway in the shaft and collar, opposite the original keyway. Re-clean parts with LOCTITE ODC-Free Cleaner & Degreaser. Apply several drops of LOCTITE 243 Threadlocker directly into the new keyway and insert key. Wipe off any excess adhesive. Assemble the components. Allow to cure. If parts are very badly worn, it may be necessary to cut new keyways. In this situation the old keyways can be filled as described below. BENEFITS Restores assembly, so it is ready for service without a major overhaul Secures the key in the keyway Eliminates micro-movements that lead to fretting Prevents corrosion

12 12 LOCTITE Industrial Shafts Rebuild and Maintenance Guide Spline Assemblies CHALLENGE Reliably securing fixed spline assemblies CAUSES Out-of-tolerance machining of components leads to micro-movement and wear Alternating loads Worst case combined loading Damage during assembly Incorrect assembly due to contamination of the parts Incorrectly specified spline drive - producing overload during operations SOLUTION Secure fixed spline assembly with LOCTITE 660 Create a chamfer on the leading edges of the socket if there isn t one, using a file or grinding wheel. Abrasive-blast the surface of the splines. Clean parts with LOCTITE ODC-Free Cleaner & Degreaser. Apply LOCTITE 660 to the shaft. Do not apply product into the socket. Immediately push the spline/toothed shaft into the socket and remove excess adhesive. Allow the adhesive to cure before returning to service. BENEFITS Restores assembly, so it is ready for service without a major overhaul Reduces scrap and costs by salvaging components Reduces downtime

13 LOCTITE Industrial Shafts Rebuild and Maintenance Guide 13 CHALLENGE Lubricate and protect sliding spline assemblies from unecessary fretting and wear CAUSES Wear will occur where there is friction and movement in the spline coupling Contamination between shaft and socket SOLUTION Apply LOCTITE Moly Paste to splines during assembly to reduce friction Clean mating surfaces before application with LOCTITE ODC-Free Cleaner & Degreaser. Coat mating surfaces with LOCTITE Moly Paste. Assemble parts. BENEFITS Withstands extreme pressure and heavy loads Prevents wear caused by friction for long-lasting assemblies Prevents corrosion

14 14 LOCTITE Industrial Shafts Rebuild and Maintenance Guide Shaft Repair Product Selector Chart APPLICATION LOCTITE SOLUTION BENEFITS PACK SIZE PG SHAFT REPAIR SOLUTION Repairing badly worn shaft LOCTITE Superior Metal Non-rusting, ferro-silicone-filled epoxy. Extremely high compressive strength and wear resistance. Sets in 20 minutes. 1 lb. Kit 4 kg Kit 6 Sleeving LOCTITE 648 A retaining compound recommended for continuous working temperatures up to 350ºF (175ºC). Fills gaps up to 0.005" in diametral clearance. Fixtures in 5 minutes. Designed for press fits requiring high strength. 50 ml 7 SECURING CYLINDRICAL AND TAPER JOINTS Press Fit - Mounting components to shaft LOCTITE 648 LOCTITE 668 Retaining Compound A retaining compound recommended for continuous working temperatures up to 350ºF (175ºC). Fills gaps up to 0.005" in diametral clearance. Fixtures in 5 minutes. Designed for press fits requiring high strength. Convenient semisolid formula. Withstands temperatures to 400ºF (204ºC). Ideal for gaps up to 0.005" in diameter. 50 ml 8 19 g stick 8 LOCTITE 609 Low viscosity adhesive for bonding cylindrical assemblies. Ideal for gap distances up to 0.005" diametral clearance. Fixtures in 10 minutes. 50 ml 8 Slip Fit - Mounting components to shaft LOCTITE 620 LOCTITE 680 High temperature resistance up to 450ºF. High viscosity securing cylindrical assemblies up to 0.015" diametral clearance. A high strength retaining compound capable of filling diametral gaps up to 0.015". Allows for more relaxed machining tolerances. 50 ml 8 50 ml 8 Mount components requiring mediumto-large gap fill LOCTITE 660 A creamy, non-running gel ideal for filling surface imperfections and worn areas. Ideal for gaps up to 0.020". 50 ml 8 Prevent bearing spinout, corrosion and component damage LOCTITE 609 LOCTITE 648 Low viscosity adhesive for bonding cylindrical assemblies. Ideal for gap distances up to 0.005" diametral clearance. Fixtures in 10 minutes. A retaining compound recommended for continuous working temperatures up to 350ºF (175ºC). Fills gaps up to 0.005" in diametral clearance. Fixtures in 5 minutes. Designed for press fits requiring high strength. 50 ml 9 50 ml 9

15 LOCTITE Industrial Shafts Rebuild and Maintenance Guide 15 APPLICATION LOCTITE SOLUTION BENEFITS PACK SIZE PG KEYED ASSEMBLIES Prevent keyway wear LOCTITE 243 Threadlocker LOCTITE 248 Threadlocker Anaerobic adhesive fills airspace, eliminating any micromovement between the parts. Oil resistant, removable strength. Convenient semisolid anaerobic adhesive fills airspace, eliminating any micro-movement between the parts. Removable; medium strength. 50 ml 19 g stick 10 LOCTITE 660 A creamy, non-running gel ideal for filling surface imperfections and worn areas. Ideal for gaps up to 0.020". 50 ml 11 Repair worn keyways LOCTITE 648 LOCTITE 243 Threadlocker A retaining compound recommended for continuous working temperatures up to 350ºF (175ºC). Fills gaps up to 0.005" in diametral clearance. Fixtures in 5 minutes. Designed for press fits requiring high strength. Anaerobic adhesive fills airspace eliminating, any micromovement between the parts. Oil resistant, removable strength. 50 ml ml 11 LOCTITE Superior Metal Non-rusting, ferro-silicone-filled epoxy. Extremely high compressive strength and wear resistance. Sets in 20 minutes. 1 lb. kit 4 kg kit 11 SPLINE ASSEMBLIES Securing fixed spline assemblies LOCTITE 660 A creamy, non-running gel ideal for filling surface imperfections and worn areas. Ideal for gaps up to 0.020". 50 ml 12 Protect sliding spline assemblies from fretting and wear LOCTITE Moly Paste Metal-free, general purpose lubricant. Lubricates and protects especially well during break-in and under high loads up to 750ºF (400ºC). 8 oz. brush-top can 1 lb. brush-top can 13 CLEANER AND PRIMER Cleaning and degreasing prior to bonding LOCTITE ODC-Free Cleaner & Degreaser Nonaqueous, hydrocarbon-based solvent for cleaning and degreasing surfaces to be bonded with adhesives, as well as any general purpose industrial cleaning. 15 oz. net wt. aerosol N/A Priming components LOCTITE 7649 Primer Use with LOCTITE retaining and threadlocking products to speed the cure on active metals or to ensure cure on inactive metals (stainless steel, aluminum, plated parts, etc.) fl. oz. bottle N/A 25 g net wt. aerosol can N/A

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