Screw and barrel alignment verification is the process of ensuring that the screw and barrel in an extrusion or injection molding machine are properly aligned. This is crucial for maintaining the quality and consistency of the final product, as well as for preventing damage to the equipment.
Screw and barrel alignment is important in the manufacturing process because it directly affects the quality of the final product. Improper alignment can lead to issues such as uneven melting, poor mixing, and excessive wear on the equipment. This can result in product defects, increased scrap rates, and higher maintenance costs.
AddUp, a joint venture created by Michelin and Fives, is a global metal additive manufacturing OEM and service provider of powder bed fusion (PBF) and directed energy deposition (DED) technologies. They have launched a suite of new process monitoring software to bolster the capabilities of the FormUp 350 PBF machine: AddUp Dashboards, Recoat Monitoring, and Meltpool Monitoring. This new software suite for its metal 3D printing technology optimizes part quality for prototyping and end-use industrial applications.
Posted by on 2022-07-06
Big Daishowa specializes in modular workholding that provides flexibility, efficiency and functionality. UNILOCK zero-point workholding provides value through versatile solutions that are simple to integrate into existing machinery and setups. Here, the company examines four tips for choosing the right workholding device.
Posted by on 2022-07-28
State of the Gear Industry Perspectives takes an in-depth look at the challenges and opportunities in gear manufacturing today and in the future. Our second installment online is an interview with Christof Gorgels, vice president, innovation and technology at Klingelnberg.
Posted by on 2023-01-30
Within the last decade, hard finishing technologies become highly relevant. Increasing the power density of a gearbox requires precisely machined gears without heat distortions. Especially in noise-sensitive applications, both honing and grinding are often applied.
Posted by on 2022-05-06
In July, Raymond J. Drago, P.E.—chief engineer of Drive Systems Technology, Inc. (DST), a mechanical power transmission consulting organization that he founded in 1976—will lead an IACET-accredited course on both the geometry and rating of involute splines of various types along with their applications. Topics under discussion include spline configuration variations, including half depth, full depth, and special function designs; both fixed and flexible spline configurations in terms of usage and design; lubrication methods, including grease, oil bath, and flowing oil, as well as coatings appropriate for various spline applications; and shear and compressive stress rating methods with analyses methodology in both equation and graphical methodology via various rating charts.
Posted by on 2022-05-29
The potential consequences of improper screw and barrel alignment can be significant. These include reduced product quality, increased scrap rates, higher energy consumption, and increased wear on the equipment. In extreme cases, it can even lead to equipment failure and production downtime.
In the industry, screw and barrel alignment is verified using various methods such as laser alignment, dial indicators, and strain gauge technology. These methods allow for precise measurement and adjustment of the alignment to ensure optimal performance.
Common methods used to measure screw and barrel alignment include laser alignment systems, dial indicators, strain gauge technology, and optical alignment tools. These tools allow for precise measurement and adjustment of the alignment to ensure optimal performance.
There are specific tolerances and standards for screw and barrel alignment, which may vary depending on the type of equipment and the specific application. These tolerances are typically defined by the equipment manufacturer and should be adhered to for optimal performance.
Screw and barrel alignment should be checked and verified regularly, with the frequency depending on factors such as the type of equipment, the operating conditions, and the production volume. In general, it is recommended to check alignment during routine maintenance and whenever there are signs of performance issues.
Planning a gearbox overhaul involves several steps to ensure a smooth and efficient process. Firstly, it is crucial to conduct a thorough inspection of the gearbox to identify any issues or areas that require attention. This may involve checking for wear and tear, leaks, or any other signs of damage. Once the inspection is complete, the next step is to create a detailed plan outlining the specific tasks that need to be performed during the overhaul. This plan should include a timeline, a list of required parts and tools, and the necessary resources and personnel. Additionally, it is important to consider any safety precautions that need to be taken during the overhaul, such as wearing protective gear or following specific procedures. Finally, it is essential to communicate the plan to all relevant stakeholders, including technicians, supervisors, and any other individuals involved in the process, to ensure everyone is on the same page and understands their roles and responsibilities. By following these steps, a gearbox overhaul can be effectively planned and executed, minimizing downtime and maximizing the gearbox's performance and longevity.
Various methods are used for analyzing lubricant film thickness in gearboxes, including optical interferometry, ultrasonic measurement, and capacitance measurement. Optical interferometry involves using light waves to measure the thickness of the lubricant film. Ultrasonic measurement uses sound waves to determine the thickness of the film. Capacitance measurement measures the dielectric properties of the lubricant to calculate film thickness. These methods provide valuable data for ensuring proper lubrication and preventing wear and tear in gearboxes. Additionally, advanced techniques such as infrared spectroscopy and atomic force microscopy can also be employed for more detailed analysis of lubricant film thickness.
Oil analysis can be a valuable tool in assessing the health of a gearbox. By analyzing the oil, experts can gain insights into the condition of the gearbox components, such as gears, bearings, and seals. This analysis involves examining various parameters, including viscosity, wear metals, contaminants, and additives. Viscosity measurements can indicate if the oil is still within the recommended range, which is crucial for proper lubrication. The presence of wear metals, such as iron, copper, or aluminum, can suggest the presence of abnormal wear or damage to the gearbox components. Contaminants, such as dirt or water, can accelerate wear and cause corrosion. Additionally, analyzing the additives in the oil can provide information about its ability to protect against wear and corrosion. By monitoring these parameters over time, oil analysis can help identify potential issues early on, allowing for timely maintenance and preventing costly breakdowns.
Screws and barrels are typically analyzed for thermal expansion using techniques such as finite element analysis (FEA), thermal imaging, and thermocouple measurements. FEA allows for the simulation of thermal expansion in the components by modeling their material properties and geometry. Thermal imaging can be used to visually observe the temperature distribution and expansion of the screws and barrels during operation. Additionally, thermocouples can be strategically placed on the components to directly measure the temperature changes and expansion. These methods provide valuable data for understanding how thermal expansion affects the performance and integrity of screws and barrels in various industrial applications.
Various solutions are available for dynamic sealing in gearbox systems. One commonly used solution is the use of lip seals, which are designed to provide effective sealing between rotating shafts and stationary housings. These seals typically consist of a flexible lip that comes into contact with the shaft, creating a barrier to prevent the leakage of lubricants and the ingress of contaminants. Another solution is the utilization of labyrinth seals, which employ a series of interlocking grooves to create a tortuous path for the fluid, thereby minimizing leakage. Additionally, mechanical face seals, also known as floating seals or duo-cone seals, can be employed in gearbox systems. These seals consist of two metal rings that are pressed together, creating a tight seal between the rotating and stationary components. Other solutions include O-rings, V-rings, and rotary shaft seals, each offering their own advantages and suitability for specific gearbox applications.
Filtration systems can be optimized for gearbox maintenance by incorporating various strategies and technologies. Firstly, the use of high-efficiency filters with fine mesh sizes and advanced media can effectively remove contaminants such as dirt, debris, and metal particles from the gearbox oil. Additionally, the implementation of bypass filtration systems can provide continuous cleaning of the oil, ensuring that it remains free from harmful particles. Furthermore, the integration of real-time monitoring and diagnostic systems can enable proactive maintenance by detecting any abnormalities or signs of wear in the gearbox. This allows for timely intervention and preventive measures to be taken, reducing the risk of unexpected breakdowns and extending the lifespan of the gearbox. Moreover, the utilization of automated filtration systems with self-cleaning capabilities can minimize manual intervention and optimize the efficiency of the maintenance process. Overall, by employing these optimized filtration systems, gearbox maintenance can be enhanced, leading to improved performance, reduced downtime, and cost savings.
Managing thermal issues in gearboxes requires careful consideration of several factors. One important consideration is the selection of appropriate lubricants with high thermal stability and heat dissipation properties. These lubricants should have low viscosity to minimize friction and heat generation. Additionally, the design of the gearbox should incorporate effective cooling mechanisms such as fins, heat sinks, or cooling fans to enhance heat transfer and prevent overheating. Proper ventilation and airflow within the gearbox housing are also crucial to dissipate heat. Furthermore, the material selection for gearbox components should prioritize heat resistance and thermal conductivity to withstand high temperatures and facilitate efficient heat transfer. Regular monitoring of gearbox temperature through temperature sensors and implementing preventive maintenance practices can help identify and address thermal issues before they escalate. Overall, a comprehensive approach that encompasses lubricant selection, cooling mechanisms, material selection, and monitoring is essential for effective thermal management in gearboxes.