Look At This Mess...

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this is my monday nightmare...anville cutter roller that cuts shingles as they go down the line...seems the bearing seized in the drive side and "oops"  it only weighs 1200 lbs  this will be a real "fun" job to type the least..going to bore out the end about 6" deep..whatever it cleans up will be the "majic" number for the shrink fit probably around 4.5"..the first inch will be around 6" id..i'll shrink it together and leave a 1/2" land to use for the weld point...as i get into it i'll post more pics..this is gonna be real expensive... Attachment 4456Attachment 4457Attachment 4458Attachment 4459Attachment 4460...zap!Last edited by zapster; 12-27-2007 at 05:21 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:Mondays suck bad enough. Now you've gotta deal with that, too!! I'm sure you can handle it zap.  - Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:NO STEP FOR A STEPPER  ZAP  just a  zap here an there and out the door
Reply:Originally Posted by prop-doctorNO STEP FOR A STEPPER  ZAP  just a  zap here an there and out the door
Reply:Man, you get all the fun work ! John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:That's gonna be fun to handle, watch yer fingers. DewayneDixieland WeldingMM350PLincoln 100Some torchesOther misc. tools
Reply:So you are going to bore out the roller to insert a new shaft section??  Is that drive pulley removable or does it have to be replicated? Then I guess the actual bearing can be knocked out and replaced and the bearing block is still good? Being nosey here.  Makes up for what I don't understand from the pics.
Reply:Originally Posted by SandySo you are going to bore out the roller to insert a new shaft section??  Is that drive pulley removable or does it have to be replicated? Then I guess the actual bearing can be knocked out and replaced and the bearing block is still good? Being nosey here.  Makes up for what I don't understand from the pics.
Reply:OK guys heres how we deal with this...seeing as there is no center hole left on the broken side..so the broken side goes into the lathe by the chuck...Attachment 4531now you indicate the roll in as close to zero as you can get it so you can turn a nice round spot for the steady rest...  Attachment 4532after the "spot" is done then you need to get the steady rest set up where it is..still near the chuck so when you flip the roll the rest is already at the right height and not off to the right or left when you flip it..you know its straight and at the right height..little tip we use old sanding belts for the roller to run on and the paper holds the oil for quite awhile..Attachment 4533now that thats done time to deal with the broken end..we put the whole assy in the press and put 50 tons to it..it would not budge..this got me   so into the saw with you..Attachment 4534held the drive pulley in the vice and hung the bearing block off the end supported by the hoist..Attachment 4535continued next post.....zap!Last edited by zapster; 12-27-2007 at 05:22 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:heres whats left after i got done with it...Attachment 4536the bearing with the siezed shaft is to the left..bearing block next to it...the drive pulley came apart wit a little "persusasion"but thats the pile...tomorrow i'll fab up the new journal out of 6" dia 24" long crs...bore shrink and weld!we'll see how that goes..later... ...zap!Last edited by zapster; 12-27-2007 at 05:22 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:That is some heavy duty back-breaking work. I thought car and truck exhaust gave me fits...that would send me to the looney bin. John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Originally Posted by MicroZoneThat is some heavy duty back-breaking work. I thought car and truck exhaust gave me fits...that would send me to the looney bin.
Reply:well today i got the hole finished bored..nice and straight..no taper Attachment 4579now on to the journal..6"od x24" longAttachment 4580heres the end thats going inside...002 bigger than the bore..(after that i just roughed down the bearing side to save weight..)Attachment 4581heat untill done..Attachment 4583and in the end even the most well thought out game plan goes out the window...Attachment 4584   i got it about a inch in and it got STUCK..all the heat in the world wont help now..by this time i'm usually    but.. i just chuckled and said "oh well"its not the first one..nor will it be the last one.. thing is... i've only done it 3 times in 2 yrs..so heres the dealsometimes it just dont work and then its time to make it work..i allways say.."its only metal..it can and will put up a good fight..but in the end it LOOSES"remember that.. ...zap!Last edited by zapster; 12-27-2007 at 05:22 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:If you could talk your Boss into getting some Liquid Nitrogen. Then use the best insulation you have around and insulate a metal 5 gal. bucket and start filling the bucket to just above what you want to insert into the other part. Please be very careful with this stuff its like -235deg F. Let that soak in the liquid Nitrogen for a hour or 2, just keep the level up in the bucket and try to keep it covered the best you can to keep it from evaporating.That would give you up to another .005 of shrinkage to help have a looser fit after heating the other part as to make it grow about the same. That would give you .008 to play with. For people that don't use #'s this small, just think of it as a piece of paper is roughly .003, just to give a guideline.When finished just make sure the 2 piece are perfectly straight and then come back in a few hours and you'll have what you wanted to achieve.Just had to put my $0.02 in on this as I've done a few hundred parts in this manner.Brett B & B Fabrication and Welding Inc.Spalding, MI.
Reply:thanks for the tip...dry ice will do the same but not so drastic..closest thing we'll see to that cold is the freezer in the fridge..........and that aint gonna fit  ...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:Anyone got a 500 ton press     Last edited by wog820; 08-16-2006 at 10:24 PM.
Reply:Incredible - Zap - I sure like following your threads - I wish I had half the knowledge to even get into a predicament like that....I welded a pipe the other day....
Reply:Originally Posted by zapsterpatience my friend patience....i get paid by the hr so i dont care... ...zap!
Reply:Zap - this job looks like the stuff they do all the time where my dad works.  Although they are a large machine job shop, they rebuild the rolls used in paper making machines primarily.  These things can be up to 10' in diameter and 65' long.  The journals in the ends get torn up quite often, so they replace them much like you are doing.  To get the old ones out of the end of the roll they Ox-lance a hole through the center of the worn out journal.  They use a hollow carbon rod with about 600 amps of DC current connected to it to get it going, then push as much oxygen as possible through the center of the rod as they push it in.  They cut 3 - 4 feet deep sometimes doing this. The replacement journals are usually machined from 4350 "triloy" which is some tough stuff.  I used a scrap chunk of it to make the spindle for one of my tubing benders, and it takes some work to machine it.  But, it is hard to scratch or ding it - tough stuff!  Like someone mentioned above they use liquid oxygen and heat to assemble the parts.They have a CNC lathe in the shop that is capable of turning  this stuff - it's huge!  When they finish the OD of a roll it has to be within .0002" - .0004" of the spec'd diameter, and usually they have a crown in the middle to compensate for flexing.  I just cannot even imagine how you can hold tolerances like that on stuff that size - let alone how you can measure it accurately enough.  It must take 2 guys to use the calipers they have that go that big!At any rate, I attached a picture of the trailer they use to haul some of these rolls in that are in the 150,000lb range.  And no, that pickup is not what pulls it - that pickup is the chase vehicle that has the remote control for the guy driving the back half of the trailer.  They had it parked there for a joke.Nice work Zap - if you ever wish to move to GA I bet you could go to work at that shop... Attached Images
Reply:at the shop now...i cut the journal off..the roller is being re-bored as i type... film @11.....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:well here is where we start again after cutting the stuck part off..into the lathe for drill and bore..Attachment 4595i bored it out so what was left in the bore (approx .010 "sleeve")came out when a little pressure as applied to the boring bar..came right out..but i saved the orig bore..Attachment 4596this time it was under the torch for 50 min..too much to hold the torch so i clamped it to the "bench" and just spun the roll every so often..went in this time no problem..Attachment 4597heres the finished weld..3/32 7018 welded "sideways" and to a 3/4" fillettIt 'Aint Going NOPLACE!!Attachment 4599its cooling now..i'll finish turning the journal in the morning..i told 'ya it puts up a good fight ..but in the end....I WIN  ...zap!Last edited by zapster; 12-27-2007 at 05:22 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:Nice work.  Great photos.  Thanks Zap.