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| Posted by: mepe ® 09/23/2005, 13:19:55 Author Profile eMail author Edit |
I am working on a bushing press issue. We are pressing (2) aluminum mounting bushings (about 2.5" diameter, 2.5" tall, slightly oval) with a rubber core into an aluminum housing at the same time. Our press is limited to 60 kN total. Due to the wide tolerance on the bushing diameter, we cannot press in dry, and require grease to push the bushings in with the press we have. But we also need to meet a minimum press out force, which the grease reduces. We have tested extensively for a perfect diameter to meet all press in/out requirements and it does not exist within the tolerances that we must keep. Can anyone suggest any sort of press method, or a product that can lubricate the bushing on the way in, and then 'set-up' to lock the bushing into place? We have tested: many different Loctite brands and lubrications, staking, setscrews, cold shrinking the bushing, chemical bonds, . all with very limited success. We must have lubrication to get the bushings in with the dimensions that we have to work with. Any advice would be appreciated. Thank you. |
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| Posted by: shiresh ® 10/17/2005, 12:02:24 Author Profile eMail author Edit |
i hope this type of fit is called interface fit. naturally the hole dia tolerance is to be smaller than the bush outer dia tolerace. the main principle in this interface fit is at two different fields. one is at cold condition and other is at hot condition. since if the both are different materials then the material starts expanding and my get crack or slips out of the hole. so while pressing in you have to calculate that the bush tolerace max should be Max pull out force/tensil strengh of the hole material. the fore and tensil strengh are vice versa. (snip - no email addresses please) or else u give me the hole dia and bush dia with respect to lenght and contact lengh and information about material i will calculate it for you. Modified by Administrator at Mon, Oct 17, 2005, 17:30:03 |
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| Posted by: Gary Kemp ® garykemp 09/29/2005, 14:14:36 Author Profile eMail author Edit |
What is the wall thickness of the bushing? |
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| Posted by: mepe ® 09/29/2005, 18:00:07 Author Profile eMail author Edit |
The wall thickness is small - around 2mm Modified by mepe at Fri, Sep 30, 2005, 12:49:58 |
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| Posted by: Gary Kemp ® 10/05/2005, 13:31:09 Author Profile eMail author Edit |
What is the pressout load you must overcome? |
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| Posted by: swearingen ® 10/06/2005, 06:39:23 Author Profile eMail author Edit |
Have you tried differential temperatures? |
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| Posted by: Gary Kemp ® 10/06/2005, 08:05:47 Author Profile eMail author Edit |
You could thread it and then use a loctite and/or stake it. A 2mm wall could accept a fine thread and have cutouts for a spanner wrench. This would eliminate the press operation and could withstand significant pullout loads. You may even go with a near interference thread. You would want to thread the bushing shell on a mandrel prior to the rubber attachment. Anyway, it may be something to consider if nothing else works.
Gary |
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| Posted by: mepe ® 10/06/2005, 18:43:42 Author Profile eMail author Edit |
We must meet a 2000lb press out minimum (breakaway force). I have brought up threading the bushing and heat/cold applications to shrink or expand the components, but the manufacturing floor has said that is not a viable option (this is for a large manufacturing plant that needs to make about 120 of these double bushing housings per hour) I agree threading would be optimum, but it would not be possible with our setup. The trouble we have seen with loctite is that 1) it does not cure when it is mixed with grease and 2) on special cases that we HAVE gotten a bushing to press with the loctite, once the loctite breaks during pressout test - thats it. There is no more retention. With the press-fit retaining the bushing, there is breakaway force, and then the residual resistance as it is presses out to hold it in place. I plan on trying dish soap, and several other more 'industrial' products from various companies to lubricate and then retain. What would be ideal is a lubruicant that, upon press-in and after time, loses its lubricity. I'm keeping my fingers crossed for the dish soap....Thank you for the continued input - any other ideas are certainly welcomed. |
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| Posted by: rowzee ® 10/18/2005, 10:55:42 Author Profile eMail author Edit |
Have you thought of using a tapered ID and tapered bushing OD? Placeing the small end towards to pull out direction. Just a thought. |
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| Posted by: swearingen ® 10/06/2005, 20:19:29 Author Profile eMail author Edit |
What about a water-based lubricant like KY Jelly? The water evaporates, and with it so does most of it's lubricating ability. Maybe after assembly, you run them through an oven to cook off the water... |
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| Posted by: Gary Kemp ® 10/06/2005, 22:18:38 Author Profile eMail author Edit |
I think a 2000 lb push out force for a 2mm wall aluminum bushing installation retained by a press fit only is pushing the envelope. Particularly over a long product life that may be seeing many load cycles. Even the best adhesives can degrade over time, particularly in an inconsistant assembly process with potential contamination. I hope a mechanical failure is not a life or injury threat. I would recommend at the least a snap ring or wire retainer. If mechanical failure is a human danger I would try for a redundant restraint. It is an interesting problem and I wish you the best with it it.
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| Posted by: jbike ® 10/18/2005, 01:39:17 Author Profile eMail author Edit |
I have used Windex in a similar setting. Also there are quite a few motorcycle handlebar grip lubricants. I don't know if you have tried to put on a pare of grips before but it is imposable with out lube, creating the same problem you have (you done want your grips to rotate) so the grip lube sets up after you put them on. Maybe it seams strange but it sounds like you are desperate |
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| Posted by: jbike ® 10/18/2005, 01:38:44 Author Profile eMail author Edit |
I have used Windex in a similar setting. Also there are quite a few motorcycle handlebar grip lubricants. I don't know if you have tried to put on a pare of grips before but it is imposable with out lube, creating the same problem you have (you done want your grips to rotate) so the grip lube sets up after you put them on. Maybe it seams strange but it sounds like you are desperate |
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| Posted by: Razor ® 12/13/2006, 20:24:36 Author Profile eMail author Edit |
Try using this oil Sunoco Sunpar 115
It has been recommended by a very liable source for pressing aluminum bushings into aluminum parts. I will also be trying this in the new year and would like to know if it works. |
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