Machining LARGE 4000 lb roll bearing journal on a Leblond Lathe

Рет қаралды 41,109

6 жыл бұрын

Sometimes it makes more sense to repair something than replace it. and when the something is a $200k, 4k lb steel roller with internal cooling baffles, it makes ALOT more sense. to complicate things a bit more this was an emergency repair for a large production facility so we had 2 days to turn this roll around (pun intended).
this particular repair was more that one guy could handle, as you'll see in the video it took most of the shop to get this job done and within the time constraint.
i did my best to document most of the repair but a few bits got away, in total, i think you get the sense of what it takes to do the job.
the biggest lathe in our shop is the only machine we had to do this job. Its a 40x240 Leblond, 20' long and swings 40" to the bed.
there are a few safety issues in the video, i know that, please keep yourself safe if you do any of this kind of thing... any comments regarding safety will be completely ignored, possibly deleted as they tend to get "unsavory"
if you're interested in more machining videos you can find them here in my playlist:
• How to BEND square met...

Пікірлер: 69

@mcremona 6 жыл бұрын

I just love stuff like this.

@RayMAKES 6 жыл бұрын

+Matthew Cremona we get a few big things like this from time to time... it's always interesting

@doubledarefan 6 жыл бұрын

If Matt had got that roller, he would have just sliced it up on his mill. Steel planks, anyone?

@RayMAKES 6 жыл бұрын

+Double Dare Fan yeah he would have!

@mcremona 6 жыл бұрын

Live edge steel slabs anyone?!

@RayMAKES 6 жыл бұрын

+Matthew Cremona HA! Even better

@jimhal5553 5 жыл бұрын

Excellent video and an even more excellent repair. I love watching people using creative solutions to complete seemingly impossible tasks. A suggestion. When doing a shrink to fit, while heating the outer part, pack the inner part in dry ice. This can be done by placing an open top cardboard box around the inner part. Crush up the dry ice and pack it into the box. It only takes 15-30 minutes to chill the inner part enough to make joining the two pieces very easy.

@RayMAKES 5 жыл бұрын

Thanks, glad you liked it

@phillhuddleston9445 2 жыл бұрын

I've done several similar but smaller jobs like that but in the 150-300 pound size range and I like it much better than production work. Time really flies by as you have to think through every step as opposed to production where once it's set up and running it's just rinse and repeat. You always feel a sense of pride after doing a job like this and seeing how it all fits together as it should if you did your job right.

@ManBearPig1968 6 жыл бұрын

Hi Ray, Words to live by...." If it's worth doing, then it's worth over doing". You have the best content, it's very technical , & usually involves old machinery. Thanks

@RayMAKES 6 жыл бұрын

Glad you liked it. sometimes i feel like people dont like the VARIED subjects of my channel, but i like all kinds of different things... it sounds like you do too

@2752226 5 жыл бұрын

You get by with what you have to work with. The beauty of a true machinist. Yes, some things are done differently than those who have newer or "better" gear but again, the beauty of manual machining. Biggest shaft I've turned was 11 ton !

@RayMAKES 5 жыл бұрын

thats way bigger than anything we have done

@ESCAGEDOWOODWORKING 6 жыл бұрын

You are a beast! Like always I sat here blown away. You're the best dude, hands down!!!

@RayMAKES 6 жыл бұрын

+ESCAGEDO WOODWORKING lol, that's Mr. Beast! Glad you liked it, wait till you see what's coming

@ESCAGEDOWOODWORKING 6 жыл бұрын

Wow...I can't imagine..

@RayMAKES 6 жыл бұрын

+ESCAGEDO WOODWORKING it's a smaller project, but something unexpected

@MichaelDrones58 2 жыл бұрын

Hey Ray, Just checking in. I hope you're doing well. Take care and Be Safe. Hope to see you soon.........👍

@bobengelhardt856 4 жыл бұрын

I'm impressed that the tailstock supported it through the shaft. That's 2000lb supported by the shaft. I'd expect some deflection, but you're the expert.

@RayMAKES 3 жыл бұрын

That is how the roll is supported, not a big deal

@PaulDesmondimakewoodthings 6 жыл бұрын

Very cool Ray. I love that you show such interesting machinery. Left me wondering what that roller is off of or what it does

@RayMAKES 6 жыл бұрын

+Paul Desmond hey Paul! glad you liked it, the roll is off a laminating machine. They extruder plastic film and then press it on to paper through this roller

@hilltopmachineworks2131 6 жыл бұрын

Man that is a loooong bed on that LeBlond. Talk about putting the tailstock to the test. Nice repair.

@RayMAKES 6 жыл бұрын

yes it is!! we dont use it all of the time but when we do, its the only lathe in the shop that can do the job

@KagakuGakusei 6 жыл бұрын

I would love to see long videos of stuff like this if at all possible.

@RayMAKES 6 жыл бұрын

+KagakuGakusei will consider it on some upcoming videos

@andrewmicas4327 6 жыл бұрын

We have done a lot of repairs like that, and also used the shrink sleeve on repair. All our roller we made had shrunk in ends, we made a ring burner i.e. 360 of heat used natural gas and compressed air worked really well. Once we set on a new manger and he decided to put in a liquid nitrogen tank to freeze ends, cost him his job because it did not work easier to get more expansion with heat , than cold. Plus that stuff was very dangerous,

@RayMAKES 6 жыл бұрын

yes its a technique we like to use, works very well

@sumising 5 жыл бұрын

Awesome video

@RayMAKES 5 жыл бұрын

Thanks

@ryanr2n2yc 5 жыл бұрын

great video. loved it

@RayMAKES 5 жыл бұрын

thanks, glad you liked it

@blackdaan 4 жыл бұрын

nice work

@RayMAKES 3 жыл бұрын

Glad you liked it

@RemyMartinVSOP 4 жыл бұрын

You could re sleeve that journal and even keyway it. Heat the sleeve and it will shrink on. Machining weld will eat your inserts in no time.

@nikolaiownz 4 жыл бұрын

Not ud you use the correct inserts. You can get tough and not hard inserts that eat throug welds like butter. I do it all the time

@EDURASTELLIBORDIGNON6806 2 жыл бұрын

Aonde a luta estava apoiada ? Tinha q estar no diâmetro maior .

@dougankrum3328 6 жыл бұрын

...I was 'the welder' in a couple machine shops....we did stuff like this ....I was often the one who had to 'install' the bearings/gears that went on the repaired shaft...we did quite a bit of stuff for a big concrete company that used rolls with the 'timken' bearing units that are used on railroad axles....when I first started working there, there was a lot of guessing about the heat and size....I tried using inside 'mike' to measure the bore while heating...saved a lot of swearing and using the 12 pound hammer....

@RayMAKES 6 жыл бұрын

Yep, it's work that needs to be done

@markreardon3472 5 жыл бұрын

I do the same type of work and have for the last 18 years. An older "wiser" guy taught me a method of making the fit when machining sleeves etc or a shaft that needs to be a shrink or press fit. Use .001 per OD inch for most press fits and when removing for instance a bull gear from a 6" shaft you can bet that it will need to be around 600 degrees F before it winks. Has always worked for me. 16 years in heavy oilfield machine work and now two in a regular job shop. I still enjoy it but it has its days.

@emilgabor88 5 жыл бұрын

Nice work. Did you recut the center after welding? how much did it worp after welding if you remember.

@RayMAKES 5 жыл бұрын

yes, we always re-cut the center, welding will make the old one useless

@martinnorbeck5961 3 жыл бұрын

When you have six guys at once telling the lift op. what to do at the same the fun begins.

@BigSkyCurmudgeon 2 жыл бұрын

too many bosses at the lift is an invitation to disaster

@robertevans6481 6 жыл бұрын

"Small gear" LOL.....

@RayMAKES 6 жыл бұрын

+Robert Evans yeah, you know how I roll

@Mini.Moto.Guy806 5 жыл бұрын

Is this to a feed mill roll? I currently fix and build feed mill rolls and this one looks similar

@RayMAKES 5 жыл бұрын

its for a laminating line, cooling and pressing plastic film to paper

@peterhinch250 5 жыл бұрын

What way did you hold the sleeve on Ray. Extra deep key or weld.

@RayMAKES 5 жыл бұрын

just a shrink fit

@BigSkyCurmudgeon 2 жыл бұрын

how would you like to shrink a 84in long cast iron barrel-48 inch diameter 24 inch bore onto a 20 ft long steel shaft that has been stepped turned to mate the cast iron bores with a .012-015 press/shrink fit? sugar mill roll shafts. then machine the cast iron to diameter and then cut a series of V-grooves usually 50degree by2-1/2 wide the entire length of the roll. total weight in the neighborhood of 50,000 lbs or more depending on the groove geometry.. can be 40-50 degrees and width/depth variable also depending on design.. in my career, i've probably turned. faced, and grooved over 100 of these puppies.

@RayMAKES 2 жыл бұрын

I wouldn't

@BigSkyCurmudgeon 2 жыл бұрын

@@RayMAKES trust me it takes a lot of heat and a big big press. to cheat on the press time, the roll bore is stepped 4 times, and the shaft is going on is step turned accordingly, so the length of pressing only amounts to 20 inches at most, gobs of white lead replacement in the bore and about 1000 tons of press force