Engraver Roller Journal Repair...

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Another Engraving roller to replace the journal on...Snapped the journal off...The customer does not want any marks whatsoever on the OD of the roller so I had to fab up a aluminum ring to shrink over the OD so I can steady rest it to drill and bore out the broken end..Here is the roller and broken journal..Weight just over 500 LBS..Broken end..Aluminum ring..Shrunk on .010 shrink..Grab the broken end in the chuck then indicate the OD in dead nuts then turn the ring to run true with the OD...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:Before taking the roller out to spin it around set up your steady rest as you would to use it on the end of the lathe..Bolt it down and use the paper over the OD and everything so when you move it down to the end of the lathe the roller is already centered and ready to go..NO guesswork needed..Make a mark on the OD and the ring so you can see if the heat from the friction is making the ring spin on ya..We can't have that now...Now just drill..Bore..Finished..I will fab up a new journal and install on Monday..Until then..I get all the fun jobs.....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:Nice work Zap.  I especially liked the second photo you posted; the one showing the fracture surface.That's a classic fatigue fracture.  You can see the beach marks all the way across the surface.  Looks like low stress, high cycle fatigue.  The area that finally ruptured (about 3 o'clock) is small compared to the total cross section of the shaft.For those interested, ASM has a good article on diagnosing fatigue failures in rotating shafts.  There are illustrations that will help you determine if the failure is due to rotational loading, torsional loading, uniform or non-uniform stresses, high or low cycle fatigue.see the link below.  I also just posted a copy of the illustration for those that don't want to plow through the technobabble.http://www.asminternational.org/pdf/...ap0502p011.pdf Attached ImagesBenson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:Good chart! ^^^^^^^^Yeah it looks like it was cracked for awhile before it gave out.....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:Cool zapster! That's the first time I've seen an aluminum shrink ring used.Does it grow back off as easily as I'm thinking it might? Duhhh?And thanks for the link A_Dab_will_do, nice catch!Matt
Reply:Originally Posted by Matt_MaguireDoes it grow back off as easily as I'm thinking it might? Duhhh?Matt
Reply:Good work as usual. I like the ring idea. I had to use another method today on a baler roller. Nothing as precision as your roller. In fact the lack of precision is what made the job harder. Since the OD wasn't round to begin with I had to use what I call a cats head. It's a pain to setup especially for the first time on that size pipe but it allows me to make a round bearing surface. Attached ImagesMillermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:Originally Posted by irish fixitGood work as usual. I like the ring idea. I had to use another method today on a baler roller. Nothing as precision as your roller. In fact the lack of precision is what made the job harder. Since the OD wasn't round to begin with I had to use what I call a cats head. It's a pain to setup especially for the first time on that size pipe but it allows me to make a round bearing surface.
Reply:Originally Posted by zapsterWay to go there Irish..We have a few of those "Cats Heads" also at the shop..I use them for shortening rear end tubes..Have not used one in years but something is telling me....Always fun trying to indicate the inside of a tube with one of those......zap!
Reply:nice work is that from the Sun or Gannet
Reply:Zap, I was very impressed with your shrink fit ring. Can't wait to see the finished job. Irish fixit, thanks the post. Now I need to build a cat's head. I'm sure I'll need one in my near future. Hope you have your baler fixed. Just replaced the bearings and guides in one a couple weeks ago. Any wonder why it didn't sound quite right  Attached Images
Reply:Originally Posted by forhireZap, I was very impressed with your shrink fit ring. Can't wait to see the finished job. Irish fixit, thanks the post. Now I need to build a cat's head. I'm sure I'll need one in my near future. Hope you have your baler fixed. Just replaced the bearings and guides in one a couple weeks ago. Any wonder why it didn't sound quite right
Reply:OK as we continue...I always move the weld point on jobs like this about 3/8" away from where the break is..Just remember to add that amount to the depth of the bore and the overall length of the broken part so it comes back out per spec..It makes no scence at all to install a new piece where the break happened..After welding and machining you can't tell where the weld was..Machine the journal to shrink fit to around .006 squeeze...Add the angle so the "V" is even..Pics will show the explination a little better...Journal fabbed up in the lathe..After heating the ring for 30 seconds it fell off so now heat the end of the roller and insert new journal..First pass..Second pass..Cap pass..Next!...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:After cooling repeat like we did with the ring..Grab the new journal..Indicate the roller in to zero..Then turn a new steady rest spot on the new journal..Set up the steady rest like before so the piece is already centered..While your at it before you spin the roller around and re-set up the steady rest give the journal on the other end a little polish job to make everyone happy..Now just center..Face off to length and finish..Last step is the 1/4"X1/8" deep and 1.5" long keyway..This is the drive side..And there you have it..All done.I get all the fun jobs.....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:Great Job... and yet another step-by-step instructional (pictorial) walk though a real-world repair.Thanks zap!Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Nice job zap!!..but how in the he!! did you do this without any CNC equipment?? http://all-a-cart.comWelding Cart Kits and accessories
Reply:Thanks for the photos! It turned out great.
Reply:Originally Posted by ZTFabNice job zap!!..but how in the he!! did you do this without any CNC equipment??
Reply:Originally Posted by forhireThanks for the photos! It turned out great.
Reply:Simply amazing zap. Always something to be learned with your threads.Thanks."The things that will destroy America are prosperity at any price, peace at any price, safety first instead of duty first, the love of soft living and the get rich quick theory of life." -Theodore Roosevelt
Reply:Originally Posted by SandySimply amazing zap. Always something to be learned with your threads.Thanks.
Reply:Looks real good Zap, are you that serious with the rosebud? Sometimes my camera shows me things I didn't see before.Also do you use a lazy man or hang the roll from a jib to do the milling? That's one of those things you work out and say to self (there has to be a better way to do this...)Matt
Reply:Originally Posted by Matt_MaguireLooks real good Zap, are you that serious with the rosebud? Sometimes my camera shows me things I didn't see before.Also do you use a lazy man or hang the roll from a jib to do the milling? That's one of those things you work out and say to self (there has to be a better way to do this...)Matt