The linear rails for high-speed gantry milling machines are mostly made of steel or cast iron. Once scratches occur, if not repaired in time, the damaged area will expand continuously, which will severely affect the overall operation of the machine tool. During the long-term operation of the machine tool, due to the continuous friction between the two contact surfaces of the linear rail kits and their friction pairs, varying degrees of wear will inevitably occur. This kind of wear will significantly reduce the machining accuracy of the machine tool and affect the production efficiency. In the past, when enterprises dealt with the worn parts of machine tools, they often adopted methods such as inlaying metal plates, using polymer materials, or direct replacement. This not only requires a large amount of precise processing but also needs to manually scrape the processing surface. The repair process is cumbersome, and the repair cycle is long.
In the current era of pursuing high efficiency and energy conservation, polymer composite materials stand out due to their unique advantages. This type of material is based on raw materials such as polymers, ultra-fine metal or ceramic powders, fibers, etc., and is compounded under the synergistic effect of curing agents and curing accelerators. The characteristics of different materials complement each other, making the comprehensive performance of the composite materials far superior to that of a single raw material. With its strong adhesive force, good mechanical properties, and excellent chemical corrosion resistance, it has become an ideal choice for the repair and anti-corrosion protection of problems such as mechanical wear, scratches, pits, cracks, leaks, and casting sand holes in metal equipment.
The internationally advanced polymer 2211F metal repair material brings a new solution to the scratch repair of the linear motion rails of high-speed gantry milling machines. Compared with traditional methods, the scratch repair using this material can be completed in just a few hours, and the operation is convenient and highly efficient. The specific repair process is as follows:
1. Heat the scratched part with an oxygen-acetylene flame (strictly control the temperature to prevent surface annealing) to fully bake out the grease that has seeped into the metal surface over the years until there are no more sparks splashing.
2. Use an angle grinder to treat the surface of the scratched part. The grinding depth should exceed 1 millimeter, and grooves should be processed on the heavy-duty linear rails, and a dovetail groove is preferable. Drill holes at both ends of the scratch to deepen them, thereby improving the stress condition.
3. Dip absorbent cotton in acetone or absolute ethanol to carefully wipe the surface to ensure it is clean and free of impurities.
4. Apply the evenly mixed 2211F material to the scratched area. The first layer should be thin and even, completely covering the scratched surface to ensure sufficient adhesion between the material and the metal surface. Then, apply the material to the entire repaired part and press repeatedly to make the material fill densely, reaching the required thickness, and the surface should be slightly higher than the Linear Guide Rail system.
5. Under the condition of 24°C, it takes 24 hours for the material to fully cure. If you want to shorten the time, you can use a halogen tungsten lamp to increase the temperature. For every 11°C increase in temperature, the curing time is halved, and the optimal curing temperature is 70°C.
6. After the material is cured, use a fine grinding stone or a scraper to trim the part that is higher than the surface of the linear slide systems until it is flat, and then the entire repair work is completed.
