XZG(B)2800 U shape linear type vibratory finishing machine

Feature:

1. Processing bowl

  • Robust stress relieved and shot peened welding construction with special ribbing
  • Easy to use T nut fastening system to install divider plates for creating multiple processing chambers in the work bowl
  • Process water distribution pipe made of stainless steel and installed across the entire length of the processing bowl
  • To reduce vibration transfer to the floor, our trough vibrators are mounted on special shock absorbers

1800 vibratory finishing machine

2. Large diameter media unload plug

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3. High wear-resistant hot poured PU lining which made from USA DuPont

2400 liter dividers vibratory tub

4. Machine frame

All our machine frames are designed and manufactured as rigid and highly load-bearing welded constructions. The special helical spring mounting design allows the vibrating process bowl to be completely detached from the base frame. Large, easily accessible hatches facilitate equipment adjustment and maintenance. Special shock-absorbing feet minimize the transmission of vibrations onto the floor.

2800 liter vibratory finishing machine

 

Operational Manual Linear Type Vibratory Finishing Machine

I. Name of product: XZG(B) 2800

Linear Type Vibratory Finishing Machine

II. Applications

The polisher is mainly used for processing parts made of metals, non-ferrous metals and nonmetals, including removing burrs and rust, rounding and polish-processing, especially suitable for polishing long parts and the parts with complicated and irregular cavities. After processing, not only there is no damage to the original shape or precision of dimensions of the processed parts, but also the precision of the roughness of the processed parts can be raised 1 to 2 grades, in addition, the microhardness on the parts’ surface can be increased, and the internal stress can be removed, thus enhancing the fatigue strength. This type of polisher is suitable for the surface polishing of large quantity and batch of medium and large-sized parts.

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III. Main specifications and parameters

1.The main specifications and parameters can be seen in Fig.1 and Table1

Fig1.

2. Table1 Parameters for XZG2800 Linear type vibratory finishing machine

IV. Main structure and working principle

The linear type of vibratory polisher XZG consists of a vibratory motor, a trough vessel (as seen in Fig.1), pedestal springs and basement. The vibratory motor is connected with the vessel by means of bolts and then together they are installed on the compression springs linked to the basement. The structure can be seen in Fig.1.

vibratory finishing tub container loading

2800 machine container loading

 

Being the main part that is vibrated in the course of polishing, the vessel should have greater rigidity, so it is made of steel plates welded together. In order to avoid scaring the parts’ surface and reduce noises the vessel is lined with rubber which is abrasion-resistant, acid and alkali- resisting, but not oil-resistant.

There are two groups of unbalanced loads on both the left and the right ends of the vibratory motor which is used to adjust the amplitude by changing the relative positions of the loads to meet the needs of polishing different kinds of parts.

When the motor’s spindle revolves at a high speed, the unbalanced loads will produce centrifugal force and tilting torque which, through the springs, cause the vessel vibrate regularly, and at the same time, the abrasive pieces and the parts in the vessel are also caused to vibrate regularly, thus the relative motion between the abrasive pieces and the parts polishes the parts.

The polishing process of the linear type vibratory polisher is a kind of vibratory grinding process in which the parts to be processed are put in the vessel where there are polishing abrasive pieces and grinding compound mixed by certain ratio. The regular vibration of the vessel causes a relative grinding movement between the abrasive pieces and the parts, thus removing the burrs from the parts, and at the same time rounding the sharp edges and polishing the surfaces of the parts.

V. Installation and adjustment

5.1. The polisher may be set up on the level concrete ground (with the thickness of the concrete greater than 10cm).

5.2. The buffers are first secured to the basement which then is set on the selected work site.

5.3. The vibratory motor has already been adjusted before leaving the factory, but the vibrating force can be adjusted according to the different requirements of grinding different parts.

VI. Operation and use

The polishing conditions are decided by the shape, size, material, purpose of grinding and the quantity of the parts to be processed.(only for reference, the polishing conditions must be decided according to the concrete situations)

6.1. Selection of the abrasive pieces for polishing:

6.1.1. For removing the burs off the cast and forged ferrous metal parts the requirements for whose surface roughness are not high, the abrasive pieces of aluminium oxide with larger graininess should be chosen which possess higher hardness, greater cutting ability and cheaper.

6.1.2.For removing the burs and abating the sharp edges of the ferrous metal parts the requirements for whose surface roughness are high (such as the parts processed by grinding, scraping and bench work), the abrasive pieces of aluminium oxide with smaller graininess should be chosen which possess certain cutting ability and stable cutting nature

6.1.3.For polishing the ferrous metal parts, abrasive pieces of aluminium oxide with even smaller graininess and stable cutting nature and very bright quenched steel balls able to extrude the parts’ surface should be chosen. For the parts which may be deformed easily, some organic abrasive materials should be added (such as wood chip, corncob, leather, hair felt, rice hull and walnut shell).

6.1.4. For removing burrs off the nonferrous metal parts, the abrasive pieces of carborundum with smaller graininess and the abrasive pieces of resin binder should be used.

6.1.5. In order to enhance the surface roughness and the metallic luster of the nonferrous parts the abrasive pieces of carborundum with even much smaller graininess, resin binder and ceramics can be used. Such organic materials as wood chip, leather and hair felt can also be used.

6.1.6. Choice of steel balls: For iron, aluminium alloy and stainless steel parts, if the requirements for their surface brightness are high, steel balls are usually used as the abrasive pieces for polishing. In this case, a new vibratory polisher of proper model and specifications must be ordered, because the steel balls cannot be used in the polisher using the ceramic abrasive pieces.

6.2. Choice of shape and size of the abrasive pieces:

6.2.1. For removing fins and burrs off the cast and forged parts, the abrasive pieces of irregular shape and large size should be chosen, whereas for finishing, the abrasive pieces of regular shape and small size should be used.

6.2.2. In the case of processing the parts that are easy to deform (such as thin sheet parts and long, thin parts), the abrasive pieces should not be too large lest the parts should be deformed by bumping.

6.2.3. When the parts of greater rigidity are processed, the abrasive pieces of any shape and size can be used, but their shape and size should not be similar to those of the parts processed to avoid the difficulty of separation.

6.2.4. When hollow parts and parts with troughs are processed, the abrasive pieces of regular shape should be chosen. No matter which kind of abrasive pieces are chosen, the large pieces must be larger than the holes and the troughs in the parts and the small pieces must be smaller than 1/3—1/5the size of the holes and the troughs for the small pieces to move freely in the holes and the troughs without blocking the way.

6.2.5.When the abrasive pieces of ceramic balls or of quenched steel balls are used to polish the circular arc surface of the parts, the radius of the ball should be a little smaller than that of the circular arc surface of the part. In order to polish the other surfaces of the part large and small balls should be used together. If ceramic balls are used for finishing, the ceramic balls should be ground by themselves in advance in a vibratory polisher for 1—2 hours to remove the burrs on them for fear that they should damage the surface of the parts.

6.2.6.When the threaded parts are processed, the abrasive pieces without cuspidal edges should be used to avoid damaging the tooth cusps, and the abrasive pieces should not be too large for fear that they should deform the threads.

For a reasonable use of the abrasive pieces attention should be paid to the following:

6.2.7.In the course of grinding compounds should be used to keep the abrasive pieces clean and sharp thus helping to remove burrs and polish parts smoothly.

6.2.8.After polishing the steel balls must be washed clean and kept from rust.

The proper and reasonable choice of abrasive pieces is a complicated and a key problem, the above-mentioned serves only as reference for the users.

6.3.The ratio of the abrasive pieces to be used to the parts to be processed:

There should be a reasonable ratio of the abrasive pieces used to the parts to be processed, otherwise, either the parts’ surfaces are scratched or the grinding efficiency is reduced and the abrasive pieces are wasted. It is proved by practice that the result of polishing is the best when abrasive pieces for polishing encloses the parts completely.

6.4.The quantity of the abrasive pieces and the parts to be added to the vessel:

The proper quantity of the parts and the abrasive pieces to be put into the vessel is that which reaches 85%—90% the total volume of the vessel. If the quantity of the mixture is too small, it’s rolling speed will be reduced, decreasing the grinding efficiency, and if the mixture quantity is too large, the mixture will overrun the vessel during grinding. The proper quantity of the mixture of the parts and the abrasive pieces in the vessel can be judged by the fact that the mixture can roll in the vessel freely and at the same time will not overrun the vessel.

6.5.The quantity of the polishing compound to be added:

The polishing compound is a kind of solution made up from different chemical compounds and plays an important role in grinding and polishing. The reasonable use of proper quantity of polishing compounds can make the processed parts bright and beautiful, adding to them metallic luster and cleaning them to protect them against rust. In a word, the polishing compound is used to clean and soften the surfaces of the parts so as to increase the polishing speed, and to reduce the striking effect on the parts.

There are many kinds of polishing compounds which should be selected according to the purpose of processing. The quantity of the polishing compound depends on the quantity of water to be added, usually 10—15 grams of polishing compound is added to each liter of water, with the minimum being used in rough grinding to remove burrs and the maximum being used for polishing. The effective work time for the polishing compound is 1 hour and the polishing compound and water should be replaced when the grinding time is longer than 1 hour. The used compound and water are first drained out of the vessel, and the abrasive pieces and the parts are washed clean, then the new compound and water are put into the vessel.

6.6. The quantity of water to be added:

The proper quantity of water to be added is about 3% the volume of the vessel. Too little water may reduce the buffering and lubricating effect, resulting in scratches on the surfaces of the parts, and too much water would cause the irregular movement of the abrasive pieces and the parts, influencing the quality of the polishing, so the quantity of water must be carefully controlled.

6.7.The determination of the grinding time:

The grinding time is determined according to the situation of the parts processing. The best grinding time is usually found by means of technological experiments so as to work out a basic table for grinding time.

6.8.Cleaning of the parts to be processed:

Before grinding the oil and the dirt must be removed from the parts to be processed, failure to do so will reduce the rubber lining’s service life and influence the grinding quality, for example, it would blacken the surface of the processed parts.

6.9.Because steel balls are easy to rust, they should be immersed in sodium nitrite solution for anti-rusting treatment immediately after the steel balls are cleaned after polishing is completed. If the steel balls have already been rusted before use, the balls must be washed in cleaning agent to remove the rust before use. The heavily rusted steel balls should not be used.

VII. Repair and maintenance

7.1.Check regularly whether the electric control system is sensitive and dependable.

7.2. Open the hoods on both ends of the vibratory motor and turn the eccentric bodies with hand, the bodies should rotate freely without any hindrance.

7.3.Switch on the machine and let it run idle, the machine should run smoothly without any strange noises. In the event of any strange sounds and hindrance which are usually caused by the wear-out of the motor bearings, stop the machine and take relative measures according to different situations such as lubricating the machine or replacing the bearings.

7.4.During operation the polisher produces violent vibration, so special attention should be paid to the loose screw bolts and, particularly, regular examination should be made of the screw bolts securing the vibratory motor. If there are any screw bolts found loose, screw them in time.

7.5.Check whether the cable from the connection box of the motor is secured, if the cable gets loose and in contact with other parts of the machine, the vibration of the machine during operation will lead to damage or even breakage of the cable.

7.6.There are unbalanced loads installed on both ends of the spindle of the vibratory motor, when the motor spins at a high speed, a very great exciting force is produced, so both the left and right bearings of the motor will bear greater loads, therefore the bearings must be lubricated regularly. A major overhaul should be given to the vibratory motor every time when it has run for 3000 hours, and the lubricant, bearings and the oil seals should be replaced.

7.7. To guarantee the bearings’ service life specified lubricant must be used, its quality should be: lithium base grease (Q/ST1002-65)ZL-3.The quantity of the grease put in the bearing should be proper, too much grease will not only increase resistance, preventing the motor from starting quickly, but also cause overheat, resulting in quick consumption of the grease, so more frequent addition of smaller quantity of grease is recommended. The lubricant should be put in at the interval of no more than 600 hours.

7.8.The vessel lining is made mainly of natural rubber, so never put strong base and acid, oil and other dissolvants into the vessel, because these substances will cause the rubber lining to be swollen and dissolved, and separated from the steel plate, damaging the rubber lining and contaminating the parts being processed. For this reason, the specified polishing compounds supplied by our factory must be used in polishing. The service life of the rubber lining varies greatly according to different purposes of polishing, parts and operation conditions. During operation, the abrasive pieces and the parts will gradually wear out the rubber, so the rubber lining is also among the consumables.

7.9. When cleaning the parts, abrasive pieces and the grinding vessel after polishing operation, do not splash water onto the bottom of the vessel to prevent water from getting into the motor.

7.10. For the places to be checked to see table 2

Table for the places to be checked

IX. Warranty period
The machine is warranted for a period of twelve months from the date of delivery. The warranty is dependent on the machine being checked and adjusted in accordance with the instructions given in the manual and is used under normal conditions.

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