Monday, April 23, 2018

Belt Polishing Head Attachment for Mud Pump Rotors

Lathe Machine Attachment

The Belt polishing head attachment is installed on the user's own standard lathe machine.    The pump rotor workpiece is fixed in the lathe’s headstock and the tailstock and is rotated by the headstock.

The Belt polishing head attachment is mounted on the lathe machines carriage, replacing the tool post. During the polishing work, the carriage moves the Belt polishing head attachment along the axial direction of the workpiece.

When attached to a standard lathe, the belt polishing attachment is moved along with the screw feed function of the standard lathe.  The mounting of the belt polishing attachment will be designed to fit to your lathe based on the drawings provided.

 

Technical Specifications

1.      Belt drive motor power: 2.2KW, variable speed, frequency conversion motor

2.      Polishing belt surface speed: 20-40 linear meters per second, step less speed control and adjustment with variable speed frequency converter

3.      Maximum belt width: 60mm wide

4.      Maximum workpiece diameter: φ 280 mm (11 inches)

5.      Minimum workpiece diameter: φ 115 mm (4.5 inches)

6.      The maximum length of the workpiece: as this is an attachment to the original equipment, the length is limited by the length of the lathe.

7.      Power supply: 380V, 50Hz

8.      Belt polishing head attachment running noise: ≤ 80db

 

Belt polishing head attachment structure

The Belt polishing head attachment consists of the following:

·       a Belt polishing head attachment seat,

·       a Belt polishing head attachment

·       The abrasive belt drive,

·       The driving wheel main shaft system,

·       The driving wheel,

·       Support arm,

·       Abrasive belt spring tensioning device,

·       Tension correction steering wheel system,

·       Belt polishing head attachment floating lifting device

·       electronic control system and other components.

 

 

The upper part of the Belt polishing head attachment seat can rotate and can be manually rotated in a range of 360 degrees.  This allows the operator to adjust the match angle of the Belt polishing head attachment to the spiral angle of the pump rotor. The proper angle of the Belt polishing head attachment is then locked with a handle.

 

When loading and unloading the workpiece, it is also necessary to rotate the Belt polishing head attachment to a position that does not interfere with the lifting of the workpiece. See below.

 

The drive motor rotates the drive wheel to drive the belt at high speed (high surface meters per minute).  The belt is under tension with a spring tensioning mechanism.

 

The diamond polishing belt contacts the work piece on the free area of the belt, between the driving wheel and the tensioning wheel.  This permit grinding and polishing and the belt conforms to the shape of the workpiece.

 

Different widths of abrasive diamond belts are used, depending on the shape of the workpiece.   Grinding a twisted-shaped screw (mud pump rotor) typically requires a narrower belt.  Rotate the Belt polishing head attachment to an angle, at which the belt is close to the helix angle of the workpiece.   Adjust the rotational speed of the workpiece and the traverse movement of the Belt polishing head attachment along the workpiece in following the helix angle.

 

Grinding the outer diameter of the screw can be done with a diamond belt width of 60mm.

 

Grinding the bottom of the valley of the screw, the width of the belt is selected according to the width of the bottom of the valley of screw. 

 

Pneumatic system: It controls the lifting and lowering of the Belt polishing head attachment and allows the Belt polishing head attachment to float.

1.      consists of cylinders,

2.      electromagnetic reversing valves,

3.      air supply components,

4.      pneumatic lines.

 

。The electrical control system consists of

1.      inverters, circuit breakers,

2.      thermal relays,

3.      intermediate relays, and

4.      operational safety knobs.

 

The polishing attachment head is built with the high-quality brands of electromechanical parts:

1.      Variable Speed Frequency Control Motor: Siemens

2.      Inverter: Delta Taiwan

3.      Bearings: Luoyang Bearing Factory

4.      Pneumatic components: Zhengtai

5.      Low-voltage electrical appliances: Delixi or Zhengtai

6.      reducer: Hangzhou Yuqiu Machinery Co., Ltd.

  Machine specifications are as per below, the machine is built custom fit to your lathe according to the specifications below, and dimensions according to the images attached.

Microfinishing machine
bexxon global pte ltd Indonesia

Microfinishing Superfinishing GEM

diamond belt grinding attachment
GEM microfinisher lishing

Microfinishing Polishing Superfinishing


GEM Microfinishing  Frequently Asked Questions

Many different terms are used for Microfinishing.  Polishing, Superfinishing, finishing and mirror finishing, also sanding or just finishing.

1)           What is Microfinishing?

Microfinishing is a finishing process that will reach any surface finish requirements. Microfinishing productively and cost efficiently achieves any Ra, Rz, Rmax, Bearing Ratio Area and other surface finish parameters that might be specified.  Microfinishing is the most consistent method of obtaining these surface finishes.

2)           How does Microfinishing work?

The Microfinishing process utilizes a precision-coated abrasive called Microfinishing Film.  Microfinishing Films are available from 0.05 micron to 180-micron mineral size. (Note:  That’s 60 mesh up to 10,000 mesh) The micro abrasives are applied to the workpiece in a constantly indexing fashion.  The abrasive is moving very slowly (approx 1” (25mm) per minute) therefore  all areas of a large roll are always in contact with new fresh abrasive. The micron grade of abrasive used determines the surface finish.

3)           What materials can be Micro finished?

Microfinishing can finish any material: from soft rubber and urethane to HVOF hard tungsten carbide. Stainless steel, copper, chrome plating, ceramic coating and cast iron

4)           What types of parts or rolls can be Microfinished?

Virtually any size part can be Microfinished. Companies are finishing fuel injector parts, transmission components, shock absorber rods, valve stems and many other small components. Paper mills are Microfinishing rolls that can be up to 5-meter diameter and 14 meter long. Very large Copper foil drums and Yankee dryer drums are also finished using this process.

5)           Can I afford to implement Microfinishing into my production process?

If a very consistent surface finish is required on your parts, this process is the most economical method. It is productive, cost efficient and easy to operate. Maintenance on machinery is very low, even in operations that are running 24 / 7.

6)           What types of Microfinishing machinery are available?


Any company can incorporate Microfinishing into their operation. Attachments can be mounted on any lathe or cylindrical grinder. These attachments are available from a 2” abrasive width up to 24” abrasive width. Many styles of production machines are also available, including thru feed and plunge Centerless, center driven, and turnkey roll finishing and custom machines built to a customer’s specification.

7)           Is this Microfinishing a new technology that is still in the experimental stage?

Microfinishing has been used for over 30 years. The automotive industry has been using this process to Microfinish camshafts and crankshafts for many years. Steel mills and paper mills have be Microfinishing rolls for over 20 years.

 

For more information contact to Bexxon Global  info@bexxonglobal.com 




microfinishing large roll
belt grinding vs microfinishing


About GEM

GEM is the leading provider of Microfinishing solutions. We take pride in offering the best service. We are dedicated to serving the needs of our customers each and every day. 

We had the first patent on the Microfinishing process and machine.  The company was started in the 1980's and have grown since then.

GEM is a proven leader in roll grinder retrofit equipment.  Hundreds of successful installations prove that the simplicity of the GEM design works.  GEM Systems can generate specific finishes very quickly with a minimum of operator training.

You can select from our standard machines to a special retro-fit design to fit your needs.