The Job Nobody Wanted...And Now I'm "IT"...

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Yaknow what I've said about being the last one to "touch" something.."Your It"Well now I'm "It"  "Just weld up the journals and re-turn them so the bearing race "taps" on..They are .005 under now"If it was only that easy.. Heres the subject..And its a mighty dangerous piece..Thats 84" worth of extremly sharp blades that shread fabric into "Microfiber"That wonderful fabric...This spins at 6 thousand R.P.M.inside a very snug stainless tube with a long slot in it for the fabric to feed into for shreading..So this has to run Dead Nuts when its done..The shoulders nearest to the roll core run true with the blades so we first have to check what the journals are "doing" when on centers..They were not doing good..They were bent .006 or so.Ok now...so before we can weld the journals we just lightly take a chip off the shoulders near the chuck So that way there I know the shoulder runs true with the O.D. and I can re-center the journals when done welding..Now that thats done (both ends) we can set it up for welding!Here is one of the bad spots on the journal..Now lookie here..After welding notice the gap that has started at the end of the weld!!    Whoever put this together did this all wrong..Now I have to fix it..Tomorrow A.M. I'm taking the big torch to the end and I'm gonna "reverse heat shrink"As the outside gets hot it should be able to be "popped out" so I can start a new end for it..If it dont co-operate..I'll "V" it out and weld it solid and start from there.. This gets more fun by the minute! I get all the fun jobs..And now I'm it!...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:whats that piece worth. plus now it has too be ground?
Reply:My boss says 35 thousand $$$$Yes it will be put in the cylindrical grinder when I get finished with it..But the trueness of it all also keeps it in balance..I'd hate to see this come apart @ 6000   ...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:when you reverse it what process will you use also what grade rod did you use
Reply:when you reverse it what process will you use
Reply:got it i just wasn't understanding that you were welding on a plug
Reply:Wow...that thing would make a gnarly mess if it came apart.It looks nasty just sitting there.Don't forget to count your fingers after you're done working on that thing zap!!- Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:Not a piece you want to touch by accident while turning in the lathe.. ouch_________________Chris
Reply:I know that piece all too well. It is a shear cylinder. It cuts the pile height for fabric. Very dangerous machine. Many people in the plant that I worked at lost fingers due to this. And it cuts so sharp, that they didnt know they were missing fingers until they saw blood. I was a maintenance tech. there, responsible for backgrinding these cylinders every week. That is one of the reasons why I left that plant, I wanted to keep my fingers in tact. Have fun working on that piece.
Reply:Have fun working on that piece.
Reply:Rule One: Fingers and Toes(all other apendages) Must Remain Attached to the Body at ALL TIMES!!!Disclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:Just curious, but what type of shaft is that? 1018,1045?  Just curious.    I always had better luck using silicon bronze to build up shafts, but that's just me.I'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......
Reply:They are just regular 'ol mild steel..I have to keep it like that.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Uhh, such blades makes me wanna go playing with them...It´s like watching the humanity biggest dream and biggest fear...I like it!At how many RPMs will you run it in the lathe? I´m also thinking that you should ask for more cash this time...after all, you´re putting 35,000 back on track My Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:I wouldn't have the stones to tinker with that thing. I'd rather give a root canal to a cobra.  Zap, I salute you!Craftsman 230a Buzz-box,  Lincoln 140T & 180T, Century K2789, PUROX W202 O/A14" cheapo chop saw that cuts straight and square!A toolbox of the cheapest Chinese tools money can buy"Real" tools all old reliable Husky/Craftsman/Proto stuff
Reply:At how many RPMs will you run it in the lathe?
Reply:Originally Posted by wallythackerI wouldn't have the stones to tinker with that thing. I'd rather give a root canal to a cobra.  Zap, I salute you!
Reply:Ok so we're back at this A.M...I heated the end up to try and get it out but to no avail...It did not budge!Oh well its time to make it one solid piece weather it likes it or not..short end..Long end..Cool off and now its time to re-center..And here is the short end done..More next post.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Now here are the bearing races that go on the shaft ends..The one with the slot goes on first...slot out..and then the smaller one..One interesting note..These 2 races are 2 diffrent sizes inside..Longer one is .0015 bigger than the smaller one..That means 2 diffrent finish sizes on the shaft..The bigger one should (and does) slide over where the smaller one goes and stop..The smaller one should not go on at all..There is .001 "press fit" for each race..but the proper way to get them on is to boil them in oil for an hr..Then slide them on and let cool before the bearings go on..Here is the longer side done..The smaller diameter on this end is for the drive sprocket..And here is the best part..Its back in the box waiting for the grinder..I'm all done with it..And there were NO injuries during this demonstration!!  I get all the fun jobs......zap!Last edited by zapster; 04-20-2007 at 05:19 PM.I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Looks like it would have been a good job for pulsed MIG, that's alot of build up.
Reply:We used the "pulsed tig feeder" method.. ...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Very nice Zapster!-Clarke 130EN-Miller MaxStar 150STL-Miller Elite 29' Roadster
Reply:35G's  how much micro fiber does it have to cut to pay that off!!
Reply:That looked like one big pain in the rear.  But, I see you handled with your usual finess.  Thanks zap.Various GrindersVictor Journeyman torch200cf Acet. 250cf oxygenLincoln 175 plus/alpha2 gunLincoln v205t tigLincoln 350mpEsab 650 plasmaWhen you can get up in the morning, Its a good day.Live each day like its your last.
Reply:Thanks guys!.. The scarey part was when I was finishing the longer journal.. The sharpness was coming at me..When I did the other end the blades were going away from me..This is what keeps "it" interesting......zap1I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.Originally Posted by zapsterThanks guys!.. The scarey part was when I was finishing the longer journal.. The sharpness was coming at me..When I did the other end the blades were going away from me..This is what keeps "it" interesting......zap1
Reply:Holy cow that's a mean instrument.  Definitely a reason to raise the warning signs around the shop!Thought red devil was originally talking about brazing a cap in his mouth! I've been looking for an opportunity to learn brazing and would've helped him out with that one!ThermalArc 185MillerMatic 180 w/ AutosetVictor Cutskill Oxy/AcetyleneThermal Dynamics Cutmaster 38and spite!
Reply:Hi guys,I am surprised no one has made comment about the circumferential weld beads on that unit. The results from the shrinking effect that are caused by that style of repair are to be believed.I am guessing the journal diameters there are around 2 to 3 ".I have seen a five inch shaft snap at that point. The  torque from the thousand horsepower generated by that turbine shaft had a bearing on the situation as well, obviously.The company engineers did the tests on the broken bit and that was their conclusion not mine.Rebuild procedures were re written to accommodate this defect.It is much slower to weld using balanced welding techniques- lay a bead then 180 then lay the bead to counter the distortion.- turn 90, lay the bead turn 180 etc.I can emphasize  with Zap .Its not fun fixing someone else's stuff up.CommentsGrahame
Reply:I can emphasize with Zap .Its not fun fixing someone else's stuff up.Comments
Reply:SIR,how much oversize did you leave for grinding?wlbrown