Repair Methods for Static Pressure Imported Bearings in Grinding Machines

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Static pressure imported bearings are known for their high precision, strong rigidity, large load capacity, and long service life. Below are some practical experiences and insights gained during the repair and testing of such bearings, which may be useful to others. 1. **Hole Saver** - Change internal savings to external savings by adding pressure gauges to monitor the pressures in the upper and lower chambers in real time. This makes maintenance and repairs more convenient, especially for clearing blockages. This approach is far superior to using internal savers. - The optimal ratio (β) should be between 1.2 and 1.5, with 1.25 being ideal based on experience. During repair, it's essential to maintain strict control over the precision of the spindle and the front and rear bearing pads, ensuring coaxiality, roundness, and taper meet specifications. The β value must be maintained according to the machine tool’s load. The e value (misalignment between the main shaft and the bearing bush) can also be determined based on the load, helping to achieve the best β value. - When the oil chamber is not equipped with a spindle, each oil outlet should have a consistent oil column height (observed visually). If the heights differ, adjust the aperture of the saver to regulate flow. For example, in a four-chamber system, the oil column in the left and right chambers should typically range from 20 to 25 mm, with small holes sized between 0.25 and 0.4 mm. 2. **Thin Film Reaction Saver** - Thin film reaction bearings offer excellent stiffness, but they may cause issues like tilting, pulling, or sudden pressure drops during operation. The most critical factor here is the thin film itself. Common causes of bearing locking or pulling include: - Plastic deformation of the film due to excessive load. - Slow response when the external load changes suddenly, leading to conflict between the shaft and the bearing. - Fatigue deformation of the film after prolonged use, altering its reaction characteristics. - To improve performance, increase the thickness of the film and replace it with fatigue-resistant materials. Typically, a rigid film of 1.4 mm is replaced with a 4 mm thick one, while a 0.05 mm tin foil paper is placed between the cavity pad. Adjust the spindle to be 0.05 mm higher than the reference position. This ensures that the spindle (grinding wheel assembly, cutting force) returns to the center automatically. 3. **Improvement of the Oil Supply System** - The oil supply system for static pressure imported bearings includes coarse and fine filtration, along with other protective components. Enhancing this system improves overall performance. - After the saver plate, connect the oil outlet to a pressure relay and pressure gauge (originally installed before the accumulator). This allows operators to monitor both chamber and inlet pressures. If the pressure difference exceeds a certain threshold, the system can prevent the shaft from locking. For example, if the inlet pressure is 2 MPa, the outlet pressure should be between 1.2 and 1.6 MPa. If it drops below 1.2 MPa, the system should stop. - Add a digital detection device to monitor resistance changes. A gap of 0.04 to 0.05 mm exists between the main shaft and the bearing bush, creating resistance. By measuring this resistance, the gap length can be determined. One pole is the bearing, the other is the shaft. This signal is then sent to a photoelectric alarm and control system amplifier, allowing control of the spindle motor’s start and stop, preventing conflicts between the shaft and the bearing.

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