Home Techonology How does the company maintain the bearings when the production is shut down?

How does the company maintain the bearings when the production is shut down?

by Uneeb Khan

Recently, I visited some bearing workshops and saw a piece of rusted and damaged bearings. Suddenly, the phrase “if you don’t maintain them before, will pile up waste after the year”. The Spring Festival is approaching, and some enterprises are planning the Spring Festival holiday. The editor would like to remind you that enterprises that plan to stop production during the Spring Festival must pay attention to the following situations of bearings:

1. Multi-roll rolling with emulsion lubrication

Especially as the backing bearing of the side support or support roller, during the Spring Festival, the bearing on the machine must be completely disassembled, cleaned, rust-proof, and sealed. Do not let the bearing stay in the equipment archway, and avoid remaining inside the bearing. Due to the long-term adhesion of the emulsion between the bearing rolling elements and the inner and outer rings, it will cause corrosion to the bearing, resulting in rust and black stripe rust marks.

The picture shows the 12-high rolling mill of a bearing factory, which was shut down for 15 days in the middle, and a set of backing bearings of the support rollers that were still in normal use were severely corroded, resulting in rust and black streaks.

The mechanical properties and bearing accuracy of the bearing material were destroyed, and the whole set of bearings was scrapped due to batch damage, spalling and burning on the second day of the resumption of production.

2. Wide-width six-high rolling mill lubricated by oil and gas or oil mist

Also, especially for the four-row cylindrical roller bearing of the support roller, be sure to disassemble, clean, prevent rust, and seal the bearing on the machine, and do not leave the bearing in the equipment arch.

At the same time, the bearing used for the backup roll, especially the bearing seat that is not assembled with the roll, must remove the residual rolling fluid inside the bearing, re-inject 2 to 3 liters of rust-proof or lubricating gear oil, and rotate the rolling elements to ensure that Each rolling element and each end face, boss and groove are lubricated and covered.

Finally, the wrapping film is closed, and be careful not to place it in a place where the sun can shine to prevent temperature difference, condensation of water vapor, and water droplets to corrode the bearing.

The picture shows the 1150 and 1450 six-high rolling mills of a bearing factory, which were shut down for 20 days in the middle, and a set of FCDP-type bearings that were still in normal use suffered severe corrosion, which directly led to the scrapping of the entire set of outer components.

The above are two cases that were scrapped due to lack of maintenance. Next, the editor will take you to see the wisdom of the front-line masters, the holiday bearing rust prevention competition.

01The most cost-effective anti-rust, after the bearing itself is anti-rust, it is then covered and sealed by a tarpaulin moistened with anti-rust oil. When the seal is opened after the year, the bearing is perfectly preserved. The outer surface of the non-rust-proof one is severely rusted, and the outer ring needs to be re-ground or scrapped. Perfection is as simple as that.

02The most practical anti-rust, after the bearing itself is anti-rust, it is covered and sealed by the wrapping film, and it is placed in a ventilated and cool place (avoid sunlight).

03The most luxurious anti-rust, the whole set of bearings is put into a special oil pool for anti-rust and stress relief to ensure that the life of the bearing is infinitely close to the limit value. Your products shine just as well.

Bearing rust prevention work can not be ignored in two aspects! Domestic bearings often ignore one of them.

Anti-rust process management

In order to ensure that the anti-rust process can be implemented conscientiously, the technical department formulates specific assessment rules according to the process requirements, and converts the component values ​​to assess the production plant. The first-level anti-rust management personnel will conduct a monthly process discipline inspection of the production plant, the management of cooling water, anti-rust fluid, cleaning fluid, and anti-rust oil, as well as the rust rate, cleanliness and oiled packaging of finished bearings. A comprehensive inspection of the management level of the rust workers and the detection of the monitoring items is carried out, the assessment is scored, and the assessment results are issued to the production plant. Hold a regular meeting of anti-rust staff once a month to summarize the company’s monthly inspections and problems, and propose improvement measures to rectify within a time limit; at the same time, it also provides opportunities for anti-rust staff to communicate and learn from each other, and build from top to bottom Start a rust prevention management network, so that the rust prevention work has a good management foundation.

Management of anti-rust auxiliary materials

The quality of anti-rust materials directly affects the quality of product processing. Therefore, when selecting anti-rust materials, the physical and chemical properties should be tested first according to the quality requirements, and then the pilot test should be carried out after passing the test. The selected anti-rust auxiliary materials are strictly tested according to the quality standards of different materials after entering the factory, and can be issued and used by the supply department after they are qualified. In the process of use, the anti-rust material and the prepared solution are regularly tested to ensure that the concentration and proportion of the solution meet the process requirements and achieve the performance. Establishing a complete material acceptance system and quality acceptance standards provides a reliable guarantee for rust prevention management.

Cooling water management

Cooling water mainly plays multiple functions such as cooling, lubrication, cleaning, and rust prevention in bearing processing. Its correct use and maintenance directly affect the surface quality of the machined parts and the service life of the tool. The cooling water used by Luozhu can be roughly divided into three types: soda water, emulsion and synthetic grinding fluid. Basically, more than 50 tons of tank fluid is used for large-scale recycling. It is easy to cause the cooling water to spoil and deteriorate, causing burns and rust of processed parts. Strengthening the scientific management of cooling water can improve its performance, ensure product quality and reduce the cost of cooling water.

(1) Sampling and testing the cooling water twice a week to understand the effective content, PH value, rust resistance, lubricity, etc. of the cooling water, and adjust and solve the problem in time.

(2) Regularly remove slag and filter to reduce the source of bacterial growth.

(3) Always start the compressed air stirring (especially on holidays) to destroy the growth environment of anaerobic bacteria and effectively prevent the reproduction of anaerobic bacteria.

(4) When replacing the cooling water, clean up the circulation pool, pipeline, return well and sterilize it.

(5) Regularly add fungicides to the cooling water to kill bacteria and prevent the generation of corrupt substances.

(6) The miscibility between different coolants is prohibited, so as to avoid the imbalance of components and affect the performance and cycle.

(7) Coordinate the relationship between the use and management of cooling water, strengthen the management and maintenance of the use site, and prevent the immersion of pollution sources.

Inter-process rust prevention management

In the process of processing, metals often come into contact with atmospheric environments such as dust, moisture and acid mist, and rust will occur. After heat treatment, the residual salt is not cleaned properly, the acid cleaning and acid printing liquid cleaning is not completely neutralized, and the demagnetization is not clean. Chips, sweat, etc. are very easy to cause bearing corrosion. Therefore, to ensure that the workpiece will not be lost during the processing, effective anti-rust measures must be taken for the bearing parts that stay between the processes.

(1) Establish a rust-proof warehouse, adopt mechanical spraying method, spray 2-3 times per shift, 10-15 minutes each time, and concentrate rust-proof treatment on bearing parts.

(2) Regularly clean all kinds of anti-rust equipment, prepare anti-rust liquid, cleaning liquid and cooling water in strict accordance with the process, regularly test, adjust, and replace on schedule.

(3) The bearing parts that need to be inspected and ground must be demagnetized first, cleaned with cleaning fluid, and then put into storage to prevent rust.

(4) After pickling or writing acid words, bearing parts must be cleaned, neutralized completely, and then treated with anti-rust water.

(5) It is forbidden to use cooling water, cleaning liquid to wash hands, wash cloths, etc., to ensure the cleanliness and performance of the liquid used, and to prolong the life of the liquid used.

(6) Do a good job in civilized production, ensure environmental sanitation, and eliminate hidden dangers of rust.

Anti-rust management of finished bearings

The finished bearing is sealed and packaged after being coated with anti-rust oil, which can avoid being affected by the atmospheric environment during storage and transportation, resulting in rust and mildew, which will affect the performance.

(1) The finished bearings are mechanically sprayed with kerosene twice, mechanically sprayed with rust-proof and lubricating dual-purpose oil, and packed with polyethylene seals.

(2) Before spraying with kerosene, before spraying with rust-proof and lubricating dual-purpose oil, filter the filter element that meets the process requirements to ensure the cleanliness of the finished bearing. The oil tank and machine tool are thoroughly cleaned once a month.

(3) When inspectors and assemblers touch finished parts and bearings, they need to apply liquid gloves to avoid rust caused by hand sweat.

(4) The finished bearing should be handled with care in the process of transportation and storage to avoid damage to the package.

(5) The assembly room and the finished bearing storage room should be dry, clean and free of pollution sources.

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