Solid Lubricant and Types of Lubricant Groove

Product Advantages

• Maintenance-Free: Long-term use without the need to add lubricating oil.
• High Load Design: Suitable for high static and dynamic loads.
• Low Friction Coefficient: Features low friction for smooth operation without stick-slip issues.
• Wear Resistance: Offers dust resistance, corrosion resistance, impact resistance, and edge load resistance.
• Shock Absorption: The metal base provides excellent shock absorption capabilities.
• Wide Temperature Range: Usable across a broad range of temperatures.
• Broad Applicability: Ideal for applications involving frequent starts, reciprocating, rotating, and oscillating movements where oil film formation is difficult.
• Longevity: Extremely low wear rate and extended service life.

Product Introduction

• Oil-Free Supply: Reduces or eliminates the need for lubricating oil, ensuring good operation under oil-less or low-oil conditions, and extending service life.
• Self-Lubricating Principle: Initially, solid lubricants on the bearing surface form a solid lubrication film through friction transfer, reducing direct contact between components, thereby protecting wear parts and extending the life of both bearings and components.

Bearing Features

• Modern Design Requirements: Designed for minimal maintenance and reliability in extreme operational environments and under maximum load conditions.
• Cost-Effectiveness: As cost pressures increase, there is a growing demand for reliable equipment and plant operations.
• Self-Lubricating System: Metal self-lubricating bearings meet the requirements for maintenance-free and self-lubrication under long-term usage, allowing for the design of reliable, long-term self-lubricating systems.
• Application Scope: Metal self-lubricating bearing materials are suitable for high-load and low-speed conditions in rotational, oscillatory, and reciprocating linear motions, also suitable for conditions where traditional lubrication is not feasible or prohibited, or in special working conditions like dust and impact.

Application Fields

• Widely Used: The products are extensively used in continuous casting and rolling mills, injection molding machines, automotive molds, bridge machinery, hydraulic industry, steel rolling equipment, mining machinery, construction machinery, communications, steam turbines, robotic arms, offshore oil platforms, and more.
• These self-lubricating bearings are designed to meet the needs of various industrial applications, especially in environments where traditional lubrication methods are unsuitable or uneconomical. By reducing maintenance and the use of lubricating oil, not only are operational costs lowered, but equipment reliability and safety are also enhanced.

Machined bronze parts

Bearing Dimensions We recommend a length-to-diameter ratio ranging from 0.5 to 2 (L/DI). For high loads or velocities, a ratio of less than 1 (L/ID) is advised. The recommended thickness should be 0.05 times the inner diameter (I.D.) plus an additional 2 to 6 mm. Bushings are chamfered to facilitate installation. The appropriate clearance, based on the diameter of the shaft, is outlined in the accompanying graph.

Machined bronze parts are components made from bronze that are manufactured to specific dimensions and tolerances by using various machining processes. Bronze is a metal alloy that typically consists of copper and tin, and it is valued for its strength, corrosion resistance, and ability to withstand high temperatures. Here’s an overview of how machined bronze parts are made based on clients’ drawings:

Step 1: Review of Client Drawings

• The first step is to carefully review the客户提供的图纸 (client’s drawings) to understand the required specifications, dimensions, tolerances, and any special features of the bronze part.

Step 2: Material Selection

• Choose the appropriate grade of bronze based on the application’s requirements. Different grades have varying properties, such as higher strength, better machinability, or enhanced corrosion resistance.

Step 3: Material Preparation

• The chosen bronze material is prepared in the form of bars, plates, or blocks, depending on the size and shape of the part to be machined.

Step 4: Machining Process

• The bronze material is then secured in a machine tool such as a lathe, milling machine, or a computer numerical control (CNC) machine.
• Various machining operations are performed, including turning, milling, drilling, tapping, and grinding, to achieve the desired shape and dimensions.

Step 5: Heat Treatment

• Depending on the application, the machined bronze parts may undergo heat treatment processes like annealing or hardening to improve their mechanical properties.

Step 6: Quality Control

• Each part is inspected for dimensional accuracy, surface finish, and any defects using measuring tools and gauges. Modern quality control may also involve the use of Coordinate Measuring Machines (CMM).

Step 7: Finishing

• After machining, the parts may go through finishing processes like polishing, buffing, or passivation to achieve the desired appearance and surface properties.

Step 8: Assembly (if applicable)

• If the bronze part is a component of a larger assembly, it may be fitted with other parts during this stage.

Step 9: Final Inspection and Testing

• A final inspection is conducted to ensure that the part meets all the client’s requirements and industry standards.

Step 10: Packaging and Shipping

• Once approved, the machined bronze parts are packaged to protect them from damage during shipping and are then dispatched to the client.

Advantages of Machined Bronze Parts

• Corrosion Resistance: Bronze is resistant to many corrosive environments, making it ideal for marine and outdoor applications.
• Wear Resistance: It has good wear characteristics, which is beneficial for parts that experience friction.
• High Strength: The alloy is strong and can withstand high loads.
• Thermal Conductivity: Bronze has good thermal conductivity, useful for applications where heat transfer is necessary.

Considerations

• Machinability: While bronze is generally easy to machine, the specific alloy composition can affect its machining characteristics.
• Cost: Bronze can be more expensive than some other metals, so cost is a consideration in applications where it’s used.
• Design Limitations: As with any material, there are design limitations to what can be achieved with bronze, which must be considered during the design phase.

Manufacturing machined bronze parts requires a combination of precision machining and quality control to ensure that the final product meets the client’s exacting standards.

The Crucial Role of Lubrication Systems in Mechanical Equipment

Lubrication systems play a vital role in mechanical equipment by minimizing friction and wear through reducing contact between shafts and bearing surfaces, avoiding temperature peaks, thus eliminating material fatigue and corrosion. Here are two main types of bearing lubrication methods and their respective advantages and disadvantages:

Manual Lubrication System Advantages:

• Simple and straightforward: Does not require complex lubrication equipment, easy to operate and maintain.
• Lower cost: Compared to automatic lubrication systems, manual systems have lower initial and operational costs.
• Flexibility: Lubrication frequency and amount can be adjusted based on actual needs.
• Suitable for low load and intermittent operations: For equipment that does not require continuous lubrication, manual lubrication is an appropriate choice.

Disadvantages:

• Requires manpower: Regular lubrication is needed, which can increase labor intensity.
• Potential for uneven application: Manual lubrication can lead to uneven lubrication, affecting bearing performance.
• Dependent on the operator: The quality and frequency of lubrication depend on the operator’s responsibility and skill.

Forced Feed Oil Lubrication Systems Advantages:

• Automated: Automatic oil supply systems reduce manual intervention and increase efficiency.
• Uniform lubrication: Ensures even distribution of lubricant to all parts of the bearing.
• Suitable for high load and continuous operations: Necessary for high-load equipment requiring continuous lubrication.
• Predictability: Timed and measured lubrication can improve equipment reliability and predictability.

Disadvantages:

• Higher cost: Initial installation and maintenance costs of automatic systems are usually higher.
• Complexity: Requires professional design and maintenance, which may need specialized technical personnel.
• Potential for failure: Automatic systems could fail due to mechanical or electrical issues.

Other Lubrication Systems: In addition to the two main methods described, there are other lubrication systems, such as:

• Oil Mist Lubrication Systems: Deliver oil in a mist form to bearings, suitable for enclosed spaces and hard-to-reach bearings.
• Oil Air Lubrication Systems: Use compressed air to transport oil droplets to bearings, suitable for high-speed and high-temperature applications.
• Grease Lubrication Systems: Use automatic or semi-automatic grease guns to periodically inject grease into bearings.

The choice of lubrication system depends on the bearing’s working conditions, the operational environment of the equipment, the feasibility of maintenance, and cost-effectiveness. The right lubrication system not only extends the lifespan of bearings but also enhances the operational efficiency and reliability of the entire mechanical equipment.