pulleys

[snowcat]

I have 2 very large and extremely expensive pulleys that have come in for repair very similar to these tho with a very different price tag, they run on a hardened splined shaft and side play has developed into the run all on the pulley, they driven off a 300hp Cummings and develop speeds around 2600 RPM, so they have to run 100%, there made of cast type unidentified, original idea was to nickel build the worn splines on the pulley then spark erode a new set of splines, after removal I now realize the shaft size is only 1 1/4 " with a 2" depth making it neigh impossible to get a tig torch any ware near it........ I think I could be looking at scrap unless someone has any ideas..........

 

[Welderpaul]

Bore out the centre and press/shrink fit an insert with the splines machined?
Sounds too obvious that.
I'm sure you'll tell me the reason why that won't work..!

 

[snowcat]

Bore out the centre and press/shrink fit an insert with the splines machined?
Sounds too obvious that.
I'm sure you'll tell me the reason why that won't work..!

yeah the centres havent got much meat till there lightened..... that would have been an option overwise........

 

[Phil@mpliron]

Hi snowcat
with the lightining is there enough meat to wire erode the centre out say about 3-5mm per side then have a sleeve wire eroded so you can knock it in carefully.

We have done this several times in the past (probably because he had 4 wire eroders). but wherever we've done this the shaft has been stepped and the main diameter is bigger than the sleeve, so the sleeve is retained between the shaft and the retaining washer. hope it helps
Phil

 

[snowcat]

that could be an option Phil, how much would something like that cost?? I was budgeting at around £300 a pulley at the mo, the pair come in new at around 2K.....

Iv only had a couple of parts eroded before in the past so it not a process I know masses about....

 

[Phil@mpliron]

Hi Snowy
I just spoke to friend who own's an edm company (Steadfast Solutions) in west bromwich (the toolroom i used to manage became insolvent in jan, another 32 blokes became statistics)
He's given me a ball park figure of £230each thats for wiring out the centre of the pulley and manufacturing a sleeve (with him supplying the steel) he did say he could reduce cost if the 2 where the same and done at same time.

Regards
Phil

 

[snowcat]

thanks phill, PM me you or your freinds contact and il get in touch.......pallet job there and back I reckon.