German FLEXBALL shaft FLEXBALL model FLEXBALL price

FLEXBALL shafts are used to support rotating parts, bearing only bending moments without transmitting torque. Some mandrels rotate, such as the axles of railway vehicles, while others do not rotate, such as the shafts supporting pulleys. Depending on whether the shaft rotates during operation, mandrels can be divided into rotating mandrels and fixed mandrels. Rotating mandrel: the shaft is subjected to bending moment during operation and rotates; Fixed mandrel: the shaft is subjected to bending moment during operation and remains stationary. According to the function of the shaft and the load it bears, it can be divided into mandrels, rotating shafts, and transmission shafts: among them, mandrels only bear bending moments without transmitting torque; rotating shafts bear both bending moments and transmit torque; transmission shafts only transmit torque without bearing bending moments, or bear very small bending moments.

FLEXBALL shaft classification and structure

Commonly used mandrels include: 1) Small taper mandrels, which have higher positioning accuracy. However, loading and unloading workpieces with small taper mandrels is inconvenient, and axial positioning is not possible, so they are only suitable for workpieces with small batches, high precision, and no axial positioning requirements; 2) Step-type mandrels tightened with nuts, suitable for clamping multiple workpieces and occasions where workpiece precision requirements are not high; 3) Expansion mandrels, which are convenient for loading and unloading workpieces and have high precision, suitable for sleeve parts with large bore tolerances. Mandrels include cylindrical, conical, elliptical ball head, inner hole, and internal thread types. In CNC turning processing, the structural shape formed by part turning is not complex, but the dimensional accuracy of the parts, especially the geometric accuracy, is required to be very high, with strict dimensional tolerances and surface roughness values for multiple diameter dimensions.

FLEXBALL shaft process characteristics

Smelting: Obtaining high-temperature, low-sulfur, pure molten iron is key to producing high-quality ductile iron. Domestic production equipment is mainly cupola furnaces, where molten iron is not pre-desulfurized; furthermore, high-purity pig iron is scarce and coke quality is poor. The process involves melting iron in a cupola furnace, desulfurizing outside the furnace, and then heating and adjusting the composition in an induction furnace. In China, vacuum direct-reading spectrometers are commonly used to detect molten iron composition. Molding: Air impact molding technology is significantly superior to clay sand molding technology, enabling the production of high-precision crankshaft castings. Sand molds made with this process have characteristics such as no rebound deformation, which is particularly important for multi-throw crankshafts. Some domestic crankshaft manufacturers have introduced air impact molding technology from Germany, Italy, Spain, and other countries, but only a few have introduced entire production lines. Electroslag casting: Electroslag remelting technology applied to crankshaft production allows cast crankshaft performance to rival that of forged crankshafts. It features short R&D cycles, high metal utilization, simple equipment, and superior product performance. Forging technology: Automated lines based on hot die forging presses and electro-hydraulic hammers represent the development direction for forged crankshaft production. These production lines generally adopt advanced processes such as precision shear blanking, roll forging (cross wedge rolling) for billet making, medium-frequency induction heating, and fine finishing with hydraulic presses. They are also equipped with auxiliary machines such as manipulators, conveyor belts, and die-changing devices with rotary tables, forming a Flexible Manufacturing System (FMS). Through FMS, workpieces and molds can be automatically changed, parameters automatically adjusted, and measurements continuously taken during operation. Data such as forging thickness and maximum pressure are displayed, recorded, and compared with set values to select the optimal deformation amount for high-quality products. The entire system is monitored by a central control room to achieve unmanned operation. Crankshafts forged using this method have fully fibrous internal metal flow lines, which can increase fatigue strength by more than 20%. Machining technology: Rough machining of crankshafts will widely adopt advanced equipment such as CNC lathes, CNC internal milling machines, and CNC turn-broaching machines for CNC turning, internal milling, and turn-broaching of main journals and connecting rod journals, effectively reducing deformation during crankshaft machining. Finish machining of crankshafts will widely adopt CNC controlled crankshaft grinders for precision grinding of journals. Such grinders will be equipped with functions such as automatic wheel balancing, automatic center rest tracking, automatic measurement, automatic compensation, automatic wheel dressing, and constant linear speed to ensure stable grinding quality. The current reliance on imported high-precision equipment is estimated not to change in the short term.

FLEXBALL shaft usage precautions

Shaft wear is the most common equipment problem during shaft use. There are many reasons for shaft wear, but the primary cause is determined by the metal properties used to manufacture the shaft. Although metal has high hardness, it has poor resilience (cannot recover after deformation), poor impact resistance, and poor fatigue resistance, making it prone to adhesive wear, abrasive wear, fatigue wear, and fretting wear. Most shaft wear is not easily detected; it only attracts attention when issues such as high machine temperature, large vibration amplitude, or abnormal noise occur. By the time it is noticed, most shafts are already worn, causing machine downtime. Repairing worn shaft ends of large equipment is a noteworthy issue. When the shaft material is 45 steel (quenched and tempered), using only surfacing welding will generate welding residual stress, which may lead to cracks or even fracture at the shaft shoulder under heavy loads or high-speed operation. Stress relief annealing is difficult to operate, has a long processing cycle, and high maintenance costs. When the shaft material is HT200, cast iron welding is also not ideal. In China, common methods for addressing shaft wear include build-up welding, installing shaft sleeves, and knurling. If downtime is short and spare parts are available, replacing with a new shaft is common, as well as using techniques such as brush plating, laser welding, micro-arc welding, or cold welding.

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