Zollern - Vacuum Investment Casting - Brochure

PLAIN BEARING TECHNOLOGYThe ZOLLERN GroupThe ZOLLERN Group is an international company withover 3000 employees. Our fields of activity include drive systems (automation, gears and winches), plainbearing technology, mechanical engineering components,foundry technology and steel profiles.CONTENTSApplications 4/5Combustion engines and piston-type machines 6Plain bearing shells 7Bushings 8Turbocharger bearings and thrust bearings 9Industrial and plant engineering 10Energy conversion machineriesTilting pad and thick-walled bearings 11Housing and pedestal plain bearings 12Special configurations/bearing metal linings and repairs 13Hydraulic componentsSliding elements 14Special industrial engineeringHydrostatic bearing systems and components 15Research and developmentApplication engineering 16Quality and environmental management 17OSTERODE BRAUNSCHWEIG HERBERTINGEN CATAGUASES, BR LES MUREAUX, FZOLLERN plain bearings – keeping everything in motionThroughout the world ZOLLERN stands for high-quality plain bearings. The international com -petition demands innovation, delivery reliability, product quality and excellent customer service.Variegated designs of special plain bearings and multilayer compound castings adapt to thespecific market demands. A glance at our productrange reveals that ZOLLERN produces suitableplain bearings for every application whether forthe purpose of generating, converting and convey-ing energy in diesel and gas engines, gearboxes,turbines and turbo-machines or in other industrialapplications.The requirement profiles of the plain bearings inmodern machine designs are as many as they are varied. It is not only the design principle of amachine but also its size and anticipated operatingconditions which have a decisive effect on thedesign of the plain bearings used and their com binations of materials. A technically efficient, economically viable plain bearing system must therefore be specially adapted to the requirementprofile of the machine. A consequence of the development of engines and machines to produce higher and higher outputs is that the plain bearingsmust accommodate increasingly high static anddynamic loadings while, at the same time, stillachieving prolonged durability in service. That iswhy the world’s leading manufacturers of enginesand machines place their trust in our products andtheir quality. 2 3PLAIN BEARING TECHNOLOGYCOMBUSTION ENGINES AND PISTON-TYPE MACHINESPlain bearing shellsThin-walled split radial plain bearings for two-stroke crosshead and four-stroke trunk piston internal combustion engines and for other piston-type machines. Generally used asmain bearings, conrod bearings and crosshead bearings, and as bearings for camshafts andcontrol shafts.Thin- and thick-walled, split, combined radial/thrust bearings (flange bearings) as main bea-rings for all kinds of piston-type machines andas bearings for camshafts and control shafts.BushingsOne-piece radial plain bearings for the pistonpins of four-stroke trunk piston internal com -bustion engines and crossheads, camshafts and control shafts, intermediate bearings, rocker arms and items of ancillary equipmentsuch as pumps – also as combined radial/thrust bearings.Turbocharger bearingsOne-piece thick-walled radial plain bearings with particular bore profiles for very high circum-ferential speeds and one-piece thrust bearingrings with special profiling for extreme axialthrust – also as combined radial/thrust bearings.Thrust bearings Thin- and thick-walled thrust bearing rings insplit and non split design, and combined axial-/radial bearings (flange bearings) for crankshafts,camshafts and control shafts. 1 2 3 41 Plain bearing shell2 Bushing3 Turbocharger bearing4 Thrust bearingsEnergy conversion machineriesTilting pad and thick-walled bearingsRadial/thrust bearings as tilting pad bearings forapplications with high circumferential speeds orthrust loadings, or as thick-walled plain bear -ings with high inherent stability and special bore profiles. Principal applications are turbines,gear boxes, turbo-compressors, fans, verticalgenerators, electrical machines, turbochargers.Plain bearings type ZZ-bearings are high performance bearings com-plying with the applicable ISO standard anddesigned on the modular principle. The broadapplication spectrum for the different types ofbearings (pedestal, flange-mounted and centreflange bearings) covers electrical machines,fans, turbines and test rigsHydraulic componentsSliding elementsValve plates and holding down devices for axialpiston pumps and motors subject to high load -ings, with high precision geometry and planeparallelism, as ready-to-install elements orsemi-finished products.Special industrial applicationHydrostatic bearing systemsRadial, thrust and combined hydrostatic bearingsfor spindle units, guides and thread gears aswell as bearings for test rigs and special pur -poses, with a variety of regulating systems;compound bearing materials for applications in special purpose machines.4 51 2 3 41 Tilting pad and thick-walled bearings2 Housing and pedestal plain bearings 3 Sliding elements4 Hydrostatic bearing systemsINDUSTRIAL AND PLANT ENGINEERINGOur production processes are aligned to thespecific requirements of plain bearings for largediesel engines, e.g. crush height measuring, fine boring for large diameters or the electro -plating processes, which are worldwide leading.Our employees in R&D, production and qualitydraw their know-how and expertise from yearsof experience in the field of plain bearing tech-nology for combustion engines and generalindustrial engineering. ZOLLERN BHW customer service is available atall times. Whether to examine and evaluate aplain bearing or merely to provide expert infor-mation on plain bearing technology or tribology.ZOLLERN BHW’s test rig technology is unique.Thanks to the so-called two-pulse concept,combined with high stress loading frequencies,prolonged operating times can be represented in short-term tests (“screening”).Environmental awareness is taken into accountby, among other things, a unique metal recyclingfacility with an adjoining quality control.COMBUSTION ENGINES AND PISTON-TYPE MACHINES6 7Plain bearing shells• designed for internal combustion engines andother piston-type machines, but also proven in other areas of general industrial machines,e.g. gearboxes and roll stands• with a ratio of wall thickness to diameter lessthan 0.06• bimetal plain bearings in materials consistingof steel/white metal or steel/aluminium, trimetal plain bearings made of steel/bronze or steel/aluminium with an additional lining• with steel supporting shells and bearing metalcoatings of between 0.5 and 3 mm and liningsof between 0.01 and 0.04 mm• type of material selected to meet the require-ments of the stress loading profile• made in exchangeable halves. When arbitrarilyassembled, the pair of bearing shells alwaysfits in such a way that, when installed, the seatcomplies with the specified prestress level• if required, compensation for housing distor-tion by adapted wall thickness progression to support the optimum bearing function, sothat the inner diameter complies with a geo-metric shape which favours the formation of a uniform lubricating film• tested with special crush height measuringmachines, which we produce also for ourcustomers. The crush height is the charac -teristic required to achieve the necessary prestress in installed condition1 2 31 Bearing shell consisting of steel/lead-bronze/electroplated layer, diameter 250 mm2 Bearing shell consisting of steel/aluminium alloy, diameter 280 mm3 Deburring of a large size bearing, diameter 940 mm4 MAN B&W 12K98ME-C two-stroke diesel engine with main, conrod and crosshead bearings made by4Bushings• for universal applications in engine and machinemanufacturing, in thin- or thick-walled designs• available in various combinations of materialsand dimensions from 50 to 800 mm • made of steel/lead-bronze or steel/white metalby the compound centrifugal casting method • made of steel/lead-bronze or steel/aluminiumbimetal strip with welded joint, with electroplatedlining as an option• with precisely turned or ground outer diameter(between centres or centreless)• with special external shape for piston pin bushings• with specially shaped grooves for oscillating movement• with precise concentricity of outer and inner diameters• with defined eccentricity of outer and inner diameters• with cylindrical bore or multi-lobe sliding profile• with special supporting cradle for crosshead bushings without lift1 2 31 Piston pin bushing made of steel/lead-bronze, diameter 190 mm2 Camshaft bushing made of steel/lead-bronze, diameter 210 mm3 Guide bushing for a piston rod made of bronze/white metal, diameter 80 mm4 Crankshaft of a piston-type compressor48 9Turbocharger bearings• radial bearings for high circumferential speeds with 2-, 3- or 4-lobe profile • thrust bearings with customized taper land profile for highest specific load• also as combined radial/thrust bearings• in fixed or floating execution• predominantly made of bearing metals on a bronze base• on request with additional sliding layer Thrust bearings• for the axial guidance of crankshafts and camshafts • ready-to-install thrust rings and combinedradial/thrust bearings (flange bearings)• split and non split thrust rings• solid bronze or aluminium or multi-layer materials with special linings• thin- or thick-walled flange bearings• materials and structure as for engine radial bearings1 2 341 Turbocharger radial/thrust bearing with multi-lobe profile2 Radial turbocharger bearing3 Crankshaft thrust washer4 Wärtsilä W6L46 four-stroke diesel engine with main- and conrod bearings, piston pin and camshaft bushingsINDUSTRIAL AND PLANT ENGINEERINGIndustrial bearings such as cylindrical radial plainbearings or multi-lobe or tilting pad bearingshave long been traditional products of ZOLLERNBHW. The former factory in Herzberg founded in1950 under the name of GMH started designingand producing so-called multi-lobe bearings atan early stage.The first tilting pad bearings were developed inthe 1970s (when the firm was trading under the name of Glyco). ZOLLERN is also recognizedas a leading manufacturer of hydrostatic plainbearings. The development of the bearing clear -ance compensating system and its pressurisingcharacteristics dates back to the early 1980s.The staff in the design and research and devel -opment departments are continuing the com -pany’s successful tradition in the field of plainbearing innovations and providing the customerwith support appropriate to the latest state of the art.The special designs of the respective hydrody - namic and hydrostatic plain bearings also under-lie the fact that we have our own dedicatedrange of machines.Our environmental awareness is reflected by,among other things, a unique metal recyclingfacility with adjoining quality control.Thick-walled radial and radial/thrust plain bearings• split plain bearings for general in dustrialapplications, e.g. gearboxes, turbines andelectrical machines• thick-walled configuration ensures high thermal stability• available in standard and non-standard sizes • standard configuration in a combination ofsteel/white metal and diameters up to 1600mm; non-standard versions in steel/bronze indiameters up to 800 mm, with or withoutadditional lining • processed to ready-to-install condition: scraping-in is generally not necessary• with bore profiles matched to the requirementprofile; cylindrical bore, 2-, 3- or 4-lobe profile,offset halves• with hydrostatic starting aid if required• with temperature or vibration measuring sensors if requiredRadial and thrust tilting pad plain bearings• for use at very high circumferential speeds oraxial load ings and general use in machinessuch as turbines, turbo gearboxes, turbo com-pressors, fans and vertical generators • dimensions and designs to ZOLLERN BHWstandard or customers’ specifications• configured for one or both directions of rotation• with hydrostatic starting aid if required• with temperature or vibration measuring sensors if required 10 111 Thick-walled radial/thrust bearings2 Combined tilting pad bearing3 Radial and axial tilting pad plain bearings4 Steam turbine with radial tilting pad plain bearings with hydrostatic lift1 2 34ENERGY CONVERSIONMACHINERIESPlain bearings type ZZOLLERN Z-bearings comprise a series of highperformance plain bearings complying with DINstandards 31690, 31693 and 31694 for a widerange of applications (electrical machines, fans,turbines and test rigs). The modular principlewas consistently applied to the different types(pedestal, flange and centre flange bearings),permitting different modules from the system to be combined at any time.The finned Z-bearing housings, which are madeof nodular cast iron GGG 40, provide the opti-mum dissipation of heat. The spherical bearingshell support was chosen so that the forcesgenerated are evenly directed into the lower part of the housing. The housings are thereforecapable of accommodating extreme stresses.They are also supplied in insulated versions inorder to prevent creeping currents.If required, additional equipment can be orderedwith the bearing, such as oil supply systems andmonitoring instruments. If desired, all parts canalso be supplied with inspection certificates(DNV, LRS, GL etc.).1 Pedestal plain bearing2 Vertical bearing3 Centre flange bearing ZM on a generator1 2ENERGY CONVERSION MACHINERIES 3Special configurations• pads made of the compound material steel/white metal (St/Z-BHW 36); in special cases,steel/lead-bronze • tilting pad thrust bearings with or withoutlevelling pieces• thrust and radial tilting pads can also besupplied as complete sets or as spare parts• we will also calculate the dimensions, numberof pads and oil flow requirements for yourplain bearing designBearing metal linings and repairs• as sliding elements for hydraulic machines,power transmission and other applications;made of compound casting as steel/white metal,steel/bronze or steel/bronze/white metal• as ready-to-install compound casting sliding elements or prefabricated steel blanks with bearing metal coating• coated by custom designed casting and application procedures• ultrasonic bonding check and dye-penetrationtest for non porosity • supply of high quality white metals for repairpurposes or liningsTypical applications: Planetary gear bolts,hydraulic cylinders for axial piston pumps andspherical plain bearings such as spherical shells for diesel engines12 131 2 31 Radial tilting pad made of copper-chrome2 Radial tilting pad bearing3 Thrust bearing padENERGY CONVERSION MACHINERIESSliding elements• valve plates and holding-down devices for axialpiston pumps and motors• made of the compound material steel/Z-BHW 46for high loadings, pulsating and vibrating stresses• outstanding wear resistance, even under excep-tional operating conditions, such as cavitation, oil corrosion and lack of lubrication• as ready-to-install parts and semi-finished products• with dimensionally accurate geometry and planeparallelism due to double-sided grinding and lapping and by monitoring the dimensional accuracy with high precision, computer aidedmeasuring instrumentsHYDRAULIC COMPONENTS142 31 Valve plate2 Holding-down device3 Control disc4 Cross section of a Parker axial piston pumpHydrostatic bearing systems and components• for machine tools• for industrial engineering• for testing and measuring systems• hydrostatic systems and components ensure the utmost manufacturing precision and thehighly efficient damping of vibrations from production processes• wear resistance ensures consistent processing precision14 15SPECIAL INDUSTRIAL ENGINEERING142 31 Hydrostatic radial/thrust bearing (rotary table bearing)2 Hydrostatic screw-type drive3 Grinding spindle unit4 Gearwheel profiling machine with hydrostatic plain bearing system• no stick-slip effects and outstanding protectionagainst crashes• compact design, thanks to the ZOLLERN bearingclearance compensating system• circumferential speeds in the bearing up to 65 m/s• thermal stability resulting from heat dissipation by way of cooled lubricating oil• available as complete systems and individualcomponents• made of compound materials steel/lead/bronze,steel/white metal, steel/aluminium and specialmaterials optimized for the intended purposeRESEARCH AND DEVELOPMENTAPPLICATION ENGINEERINGThe plain bearing – nothing new sinceLeonardo da Vinci?While the principle remains unchanged, tools and materials, by contrast, are new and ultra-modern. High precision computing methods,such as FEM and EHD, deliver data for designwork based on the 3D-CAD method and, in conjunction with competent application know-how, give rise to the optimum solutions to problems – whether in respect of prototypes,individual components or mass produced parts.Whether it be the design of a bearing for a newmachine or engine associated, needless to say,with the appropriate choice of material, or anincrease in the output of an existing machine, atailor-made configuration always takes pride ofplace. Hydrostatic, hydrodynamic or elasto-hydrodynamic, the specific application decideson the appropriate technology.Test rig trials serve to verify the proposed solution.ZOLLERN BHW possesses one of the largest andmost modern plain bearing test rigs in the world,which permits all types of stress loadings to besimulated. Even specific preliminary developmentis possible involving the actual bearing housing.Increasing demands on the efficiency of the bear -ings in modern engines and machines are our incitation to develop new plain bearing materialsand designs. High stress loading capacities, pro-longed durability and the protection of the shaft in the event of damage are just as essential devel -opment objectives as economical and reliable pro-duction methods.1 21 Radial tilting pad bearing with controlled lubrication and hydrostatic system2 Exploded view of Fig.13 Test rig for engine bearings316 17Customer satisfaction takes top priority –quality and environmental protection areour demandFor the production of high quality products andeffective process orientation in any company, theintroduction of a quality management system(QMS) is an indispensable prerequisite. For thisreason, ZOLLERN introduced DIN EN ISO 9001 certification for the optimum integration of qualityand environmental protection, with the result thatthe successful implementation of compliance with the standard is consistently checked by anindependent certification company. Well trainedresponsible employees are essential for high quality workmanship and the continuous, success-ful striving for progress. ZOLLERN meets exactingcustomers’ requirements and quality standardsthrough the use of modern methods, proceduresand production units.Our standards of care for employees and theenvironment are equally as high as our stand -ards of quality. In this context, we do not only implement our guidelines on innovativeways and means of protecting the environmentand our staff, but also regularly monitor andevaluate the effects of our activities on manand the local surroundings. Environmentallyconscious behaviour is a duty – for everyone at ZOLLERN.1QUALITY AND ENVIRON MENTALMANAGEMENT1 Surface measuring of a bearing shell2 Micrograph of a lead-bronze/electroplated layer specimen3 Certification in accordance with DIN EN ISO 9001:200032ZOLLERN plantsBraunschweig plantZOLLERN BHW GleitlagerGmbH & Co. KGOsterode plantZOLLERN BHW GleitlagerGmbH & Co. KGBrazil plantZOLLERN Transmissoes MecanicasLTDAFrance plantZOLLERN TLC SASHerbertingen plantZOLLERN GmbH & Co. KGHeustraße 1D-88518 HerbertingenDorsten plantZOLLERN Dorstener AntriebstechnikGmbH & Co. KGAulendorf plantZOLLERN Maschinenbauelemente GmbH & Co. KGSteel ProfilesPostfach 12 20D-72481 SigmaringenTel. +49 75 71 70 24 6Fax +49 75 71 70 27 5eMail zst@zollern.deFoundry TechnologyPostfach 12 20D-72481 SigmaringenTel. +49 75 71 70 44 0Fax +49 75 71 70 60 1eMail zgt@zollern.deLaucherthal plantZOLLERN GmbH & Co. KGTransmission TechnologyAutomationTel. +49 75 86 95 95 86Fax +49 75 86 95 95 85eMail zht@zollern.deGears and WinchesTel. +49 75 86 95 95 47Fax +49 75 86 95 95 75eMail zat@zollern.dePlain BearingTechnologyTel. +49 75 86 95 95 20Fax +49 75 86 9597 15eMail zlt@zollern.dePlain Bearing Technology62, Rue Pierre CurieB.P.No 1055F-78131 Les Mureaux CEDEXTel. +33 1 34 74 39 00Fax +33 1 34 74 28 52eMail infoTLC@zollern.comPlain Bearing TechnologyPostfach 32 13D-38022 BraunschweigTel. +49 53 12 60 50Fax +49 53 12 60 53 00eMail bhw@zollern.dePlain Bearing TechnologyAv. Manoel Inácio Peixoto, 2147BR-36771-000 Cataguases MGTel. +55 32 34 29 53 02Fax +55 32 34 29 53 26eMail zollern@zollern.com.brTransmission TechnologyGearsHüttenstraße 1D-46284 DorstenTel. +49 23 62 67 0Fax +49 23 62 67 40 3eMail zda@zollern.dePortugal plantZOLLERN & ComanditaFoundry TechnologyRua Jorge Ferreirinha, 1095Apartado 1027P-4470-314 Vermoim MAIATel. +351 22 94 14 68 1Fax +351 22 94 14 69 5eMail zcp@zollern.ptSoest plantZOLLERN Aluminium-Feinguss SoestGmbH & Co. KGFoundry TechnologyOverweg 15 D-59494 SoestTel. +49 2921 7896-0Fax +49 2921 7896-17eMail www.zollern-afs.deinfo@zollern-afs.deSales officesFranceZOLLERN S.à.r.l13, Rue AllwiesF-57200 SarregueminesTel. +33 3 87 95 35 14Fax +33 3 87 95 35 21eMail zollernsarl@wanadoo.frwww.zollern.fr Great BritainZollern UK LimitedCastle HillKenilworthGB-CV8 1NBTel. +44 19 26 51 54 20 Fax +44 19 26 85 34 11eMail sales@zollern.co.uk www.zollern.co.ukItalyZOLLERN Italiana S.r.L.Via della Ciocca, 9 I-21026 Gavirate (VA)Tel. +39 03 32 46 20 59Fax +39 03 32 46 20 67eMail info@zollern.itwww.zollern.itNetherlandsZOLLERN Nederland B.V.Postbus 134NL-5150 AC DRUNENTel. +31 41 63 22 92 0Fax +31 41 63 20 93 6eMail zollern@zollern.nl www.zollern.nlRussiaZOLLERN Ltd.115114, Russia, MoscowDerbenevskaja nab., 11, ASector 2, Office 66Sweden plantZOLLERN Norden ABP. O. Box 233SE-73224 ArbogaTel. +46 58 91 60 35Fax +46 58 91 20 02eMail info@zollern.sewww.zollern.se USA plantZOLLERN North America L.P.283 Lockhaven Drive Suite 204Houston TX 77073USATel. +1 71 36 73 79 02Fax +1 71 36 73 79 50eMail zollernna@aol.com Plain Bearing TechnologyRolandsweg 16 – 20D-37520 Osterode am Harz Tel. +49 55 22 31 27 0Fax +49 55 22 31 27 99eMail bhw@zollern.de Romania plantS.C. Zollern S.R.L.0317235 Pecica FNFerma 20Arad - RomaniaMechanical Engineering ComponentsPostfach 12 65D-88322 AulendorfTel. +49 75 25 94 81 30Fax +49 75 25 94 81 00eMail zmb@zollern.deChina plantZOLLERN (Tianjin) Machinery Co., LTD.Transmission TechnologyNo. 79, 11th Avenue TEDA 300 457 TianjinPeoples Republic of CHINATel. +86 22 25 32 38 11Fax +86 22 25 32 38 10eMail sales@zollern.sina.net18 19CONTACTZOLLERN Plain Bearing TechnologyZOLLERN BHW Gleitlager GmbH & Co. KGPostfach 32 13D-38022 BraunschweigTel. +49 53 12 60 50Fax +49 53 12 60 53 00eMail bhw@zollern.de www.zollern.comwww.revoLUZion.deZOLLERN BHW Gleitlager GmbH & Co. KGPostfach 32 13D-38022 BraunschweigTel. +49 53 12 60 50Fax +49 53 12 60 53 00eMail bhw@zollern.dewww.zollern.comZ529 10.2011 Errors and Omissions excepted.