Customer's Challenge

A client from Malaysia approached Metal Machines for an on-site machining solution for one of their ball mill’s bearing mounting flanges. After reviewing the engineering drawings and GD&T requirements, we identified a significant challenge: ensuring the centering and parallelism of the flange, which are critical to the longevity of the bearings.

The complication arose due to the inability to use conventional measurement tools without lifting the heavy mill drum. Additionally, removing parts of the mill to facilitate the measurements would extend the shutdown period and potentially introduce risks associated with the dismantling process.

Solution

To avoid unnecessary dismantling and downtime, Metal Machines employed the Faro laser tracker to capture precise measurement points and create a 3D model of the drum using Spatial Analyser software. This technology allowed us to accurately determine the drum’s center and the bearing plane at M1. Using this data, our on-site machining team was able to adjust the machine setup to ensure proper alignment with the rotating axis of the drum.

The machining scope included precision machining of the new bearing mounting flange, followed by drilling and threading of the mounting holes. The entire job was completed within a week, allowing the client to install the new bearing and restart the ball mill according to schedule.

Benefits

Metal Machines went above and beyond to ensure the success of the project by thoroughly studying the engineering requirements and applying advanced measurement technologies. Our expertise ensured that both bearing mounts were perfectly aligned, preventing potential premature bearing failures and extending the operational lifespan of the ball mill.