cip engineering manual

7/31/2019 CIP Engineering Manual

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Te inormation guide in this engineering section enables the designer to establish parameters

which will provide maximum perormance o a bearing in the application. Columbia Industrial Products provides technical assistance on material selection and overall design.

During composite bearing selection there are many efects on the bearing to take intoconsideration including: CIP Composite bearings operate at diferent press ts and running clearances than bronze or other metal bearings; Composite bearings require a heavier press t to retain the bearing in the housing; and running clearances are larger in order to reduce heat buildup in the bearing.

Recommended shat materials are stainless steels or hardened steel. Te suggested minimumhardness is Rockwell 80B. Te surace nish should be rom 4-32 micro-inches (0.7 Ra).Hard chrome plating may cause premature wear and should be avoided. Holes in the shat or greasing should also be avoided as the edge o the hole could cut the bearing. Te bearing housing should have a chamer or lead-in. Te installer should use a press-in, draw-in orreeze-in method.

Do not hammer-in; bearing may become damaged. Bearing wall thickness is very important.Te correct wall thickness gives the bearing the proper strength to stay in the housing. Useable E as a guide or proper wall thickness. Te ollowing Calculation pages and ables willguide you through sizing a composite bearing.

Te rst step in sizing a bearing is to gatherthe correct inormation. Use the ApplicationQuestions sheet or this task.

CIP Composites - Engineering Manual

Engineering Manual - Oct. 2010 1

CIP Custom Bearings



Application/ype o Machine_______________________________________

Current Bearing being used_________________________________________

Shat Diameter Max _______________________ Min____________________

Shat Material____________________ Shat Finish_____________________

Housing Diameter Max ______________ Min ________ Length__________

Housing Material_________________________________________

What Kind o Environment? Wet (water) _______________ Dry _____________

Caustic ____________ Dusty _______Other_________________

emperature at bearing____________

Shat RPM __________________ Load in Pounds_________________

Hours o operation per day _______ Intermittent _______________

I intermittent, how oten does shat stop ___________________________

OR, how oten does the shat operate, ___________ times per ___________min

Rotation 360° __________ or Oscillating __________

How many bearings ______________ How Soon Needed____________________

Your name & phone #________________________________________________

Application Questions - CIP Composites




Shat Diameter Max ____________ Min ____________

Housing Diameter Max ____________ Min ____________

Consult able A for Press Fit dimension:____ able B for Min Running Clearance dim: ___

Consult able C for Machining tolerances: _____ Termal Expansion as Required: ______

Consult able D for Bore closure percentage absorbed: % A=__________ Value A = _______Absorbed is, interference or press (say .004” (0.1mm) for a 3 1/2” (89mm) shaft with .40” (10.1mm) wall) minus 20%of the .004” (0.1mm) or .0008” (0.02mm). e .0008” (0.02mm) is the amount that the interference or press will be reduced from the 100% or .004” (0.1mm). So the ID will shrink by .0032” (0.08mm) not .004” (0.1mm). e wall thickness is the control over the amount of press absorbed.

Calculations (M = Machine o)

Housing Max + Press Fit = Bearing OD Min(M) + machine olerance = Brg OD Max(M)__________ + ________ = _____________ + ______________ = __________

Shaft Max+(Brg OD Max - Housing Min)+(Min Clear + Termal) - Absorbed Bore)= Brg ID Min (M)______ + (_______ - _______) + (_______+_______) - _______) = __________

Brg ID Min + Mach olerance = Brg ID Max (M)________ + ___________ = ___________

Brg ID Min - (Brg OD Max - Housing Min) + Absorbed Bore Close = Brg as Fit ID Min________ - (________ - _________) + ________________ = _______________

Brg ID Max - (Brg OD Min - Housing Max) = Brg as Fit ID Max________ - (________ - ________) = _______________

Brg as Fit ID Min - Shaft Dia Max = Clearance As Fit Min_____________ - __________ = ___________

Brg as Fit ID Max - Shaft Dia Min = Clearance As Fit Max_____________ - __________ = ___________

See able E and Check Wall Tickness Minimum

Brg OD Max - Brg ID Min = Wall Tickness MaxBrg OD Min - Brg ID Max = Wall Tickness Min________ - ________ = ________________________ - ________ = ____________


Bearing Size Calculations




Calculation Tables A




Calculation Table B




Calculation Tables C

General Machining Tolerances

* For calculating bearing size, use machining tolerance total.Total tolerance is equal to twice the tolerance in the chart.(For bearing .75 x 2 x 7” the total tolerance for calculation = 2 x .002”

or .004”)

Length (metric) *

12.7-101.6 101.6-203.2 203.2-304.8 304.8-457.2 457.2 +

12.7-76.2 +/- .051 +/- .051 +/- .076 +/- .101 +/- .127

76.2-177.8 +/- .051 +/- .051 +/- .076 +/- .101 +/- .127

177.8-304.8 +/- .051 +/- .051 +/- .101 +/- .101 +/- .127

304.8-431.8 +/- .076 +/- .076 +/- .101 +/- .101 +/- .127

431.8-812.8 +/- .127 +/- .127 +/- .152 +/- .152 +/- .178 D i a m e t e r ( m e t r i c )

Length (inches) *.50 - 4 4 - 8 8 - 12 12 - 18 18 +

.50 - 3 +/- .002 +/- .002 +/- .003 +/- .004 +/- .005

3 - 7 +/- .002 +/- .002 +/- .003 +/- .004 +/- .005

7 - 12 +/- .002 +/- .002 +/- .004 +/- .004 +/- .005

12 - 17 +/- .003 +/- .003 +/- .004 +/- .004 +/- .005

17 - 32 +/- .005 +/- .005 +/- .006 +/- .006 +/- .007 D i a m e t e r ( i n c h e s )




Calculation Tables D



TABLE E

Minimum Wall Thickness


Calculation Table E

INCHES MM

Shaft OD Min Wall Thickness Shaft OD Min Wall Thickness

.38 to 1.00 .06 9.6 to 25.4 1.52

1.10 to 2.00 .10 27.9 to 50.8 2.54

2.10 to 3.00 .14 53.3 to 76.2 3.56

3.10 to 4.00 .20 78.7 to 101.6 5.08

4.10 to 6.00 .25 104.1 to 152.4 6.35

6.10 to 8.00 .30 155 to 203.8 7.62

8.10 to 11.00 .40 205.7 to 279.4 10.16> 11.10 .48 > 280 12.2




PV - Limits - CIP Composites



Series 100 & 200 GradesOperating temperature range ………………. -40° - 200° F (-40° - 93°C)Coecient o thermal expansion ………….... 68° - 200°F (20° - 93°C)

Normal to Laminate (bearing diameter) ..... 3.5 x 10-5 /∆ °F (1.9 x 10-5 /∆°C)Parallel to Laminate (bearing length) ……. 1.8 x 10-5 /∆ °F (1.0 x 10-5 /∆°C)

Series 300 GradeOperating temperature range ………………. -40° - 400°F (-40° - 204°C)Coecient o thermal expansion …………… 68° - 400°F (20° - 204°C)

Normal to Laminate (bearing diameter) …. 4.0 x 10-5 /∆ °F (2.2 x 10-5 /∆°C)Parallel to Laminate (bearing length)……. 2.0 x 10-5 /∆ °F (1.1 x 10-5 /∆°C)

Example Termal Expansion Calculation

Material: CIP 100 Running emperature: 200°F (93°C) Wall Tickness: 0.250 (6.35mm)

∆ = Running emp – 68°F(20°C)∆ = 200°F – 68°F = 132°F change

2 x Wall Tickness x Coecient x ∆ = Additional Clearance2 x 0.250” x 0.000035 x 132°F = 0.0023”2 x 6.35mm x 0.000019 x 73°C = 0.018mm______________________________________________________________________________

For operating temperatures exceeding Series 100 & 200 grades, use Series 300 to 400° F (204°C) with a compressivestrength of 35,000 PSI (241 MPa). Series 300 is available with the same solid lubricants as the standard grades.

As is common with all resin bonded fabrics, CIP has a low thermal conductivity. Under normal circumstances fric-tional heat is removed via the mating metal surface. However, in cases where shafts or housings are conducting heatto the bearing assembly, the lubricant must be sucient to remove both frictional and conducted heat.

Te removal of frictional heat may be improved, particularly in dry running applications, by using the housing as

the main heat conductor. Te wall thickness of bearings should be kept to a minimum in order to improve heat dis-sipation.

Termal expansion of CIP material is greater than that of most metal alloy bearings and the characteristic must betaken into account in designs for higher temperature applications.


Thermal Expansion - CIP Composites



CIP Composites are readily machinable by conventional machining techniques and, as a general

guide, may be treated as bronze, but should be machined dry without coolant.

For turning, tungsten carbide-tipped tools should be used to obtain a ne nish. To achieve a ne n-

ish use 3M Scotch-Brite Finishing Flap Brush Grade 5A VFN #01162. High-speed steel tools can be used formachining where accuracy below .005” (.12mm) is not required and for small quantity production.

CIP composites are completely non-toxic, 100% bearing material with no llers (calcium carbon-

ate). It is advisable to use adequate dust extraction when machining CIP composites.__________________________________________________________________

Cutting Angles o urning

op Rake 0° to 6°

Side Rake 5° to 8°

Front Rake 4° to 5°

__________________________________________________________________

US - Speeds or Cutting

Normal for surface nish 22 to 26 feet/second

US - Speeds or Feed

First pass/roughing .015 to .035 inches per revolution

Last pass/nishing .010 to .015 inches per revolution

__________________________________________________________________

Metric - Speeds or Cutting Normal for surface nish 6.71 to 7.92 m/second

Metric - Speeds or Feed

First pass/roughing .38 to .89 mm per revolution

Last pass/nishing .25 to .38 mm per revolution


Machining - CIP Composites



Application/ype o Machine_________est Bearing_________________

Current Bearing being used_________________________________________

Shat Diameter Max ______2.500”___________ Min____2.498”___________

Shat Material____316 SS_______ Shat Finish___32 (0.7Ra) or better____________

Housing Diameter Max __3.004”______ Min _3.000”__ Length__3.0”____

Housing Material__Cast Steel____________________________

What Kind o Environment? Wet (water) _________ Dry _____X_____

Caustic ____________ Dusty _______Other_________________

emperature at bearing___130°F (55°C)____

Shat RPM ____45________ Load in Pounds___680 lbs / 308 kg__________

Hours o operation per day __18___ Intermittent __No; Constant__

I intermittent, how oten does shat stop ___________________________

OR, how oten does the shat operate, ___________ times per ___________min

Rotation 360° __ Yes___ or Oscillating _No_____

How many bearings __200_____ How Soon Needed___4 weeks__________

Your name & phone #________________________________________________


Sample Application Questions

CIP Composites



Shat Diameter Max: 2.500” Min: 2.498”

Housing Diameter Max: 3.004” Min: 3.000”

Consult able A or Press Fit dimension: 0.006able B or Min Running Clearance dim: 0.006Consult able C or Machining tolerances: 0.004Termal Expansion as Required: 0.0018Consult able D or Bore closure percentage absorbed: % A= 10% Value A = 0.015

Absorbed is, interference or press (say .004” for a 3 1/2” shaft with .40 wall) minus 20% of the .004” or .0008” . e .0008” is the amount that the interference or press will be reduced from the 100% or .004” . So the ID will shrink by .0032” not .004” . e wall

thickness is the control over the amount of press absorbed.

Calculations (M = Machine o)

Housing Max + Press Fit = Bearing OD Min(M) + machine olerance = Brg OD Max(M)3.004 + .006 = 3.010 + .004 = 3.014

Shat Max+(Brg OD Max - Housing Min)+(Min Clear + Termal) - Absorbed Bore)= Brg ID Min (M)2.500 + (3.014 – 3.000) + (.006 +.0018) - .0006 = 2.5212

Brg ID Min + Mach olerance = Brg ID Max (M)

2.5212 + .004 = 2.5252

Brg ID Min - (Brg OD Max - Housing Min) + Absorbed Bore Close = Brg as Fit ID Min2.5212 - (3.014 – 3.000) + .0006 = 2.5078

Brg ID Max - (Brg OD Min - Housing Max) = Brg as Fit ID Max 2.5252 - (3.010 – 3.004) = 2.5192

Brg as Fit ID Min - Shat Dia Max = Clearance As Fit Min2.5078 - 2.500 = .0078

Brg as Fit ID Max - Shat Dia Min = Clearance As Fit Max 2.5192 - 2.498 = .0212

See able E and Check Wall Tickness Minimum

Brg OD Max - Brg ID Min = Wall Tickness Max Brg OD Min - Brg ID Max = Wall Tickness Min3.014 - 2.5212 = .246 3.010 - 2.525 = .242


Sample Bearing Calculations

CIP Composites



CIP Materials - Oct. 2010 1

CIP Material Grades

Description for how to formulate CIP Composite materials

CLOTH/TEXTILES ADDITIVES/LUBRICANTS RESIN/SYSTEMS

Polyester = 1 None = 0 Standard = 1100%

Polyester & = 2 Graphite = 1 Marine = 2PTFE 50/50

Nomex = 3 Moly = 2 High Temp = 3

100%

PTFE = 4 PTFE = 3 Enhancement = A

100%

Graphite & = 4 Enhancement = B

PTFE

PTFE & = 5

Moly

In following section you will nd ve (5) examples of CIP Composites and their physical properties. These are

the most commonly used textile/resin combinations for bearings and wear pads. For additional material codes

and physical properties please contact Columbia Industrial Products directly.



Columbia Industrial Products offers an additional additive to the resin mixtures:

ENHANCEMENT A and ENHANCEMENT B.

Both enhancements are nonammable, chemically inert polymer additives which increases the performance of

CIP Composite materials specically in its physical properties.

Benets

• Wear & Abrasion Resistance

• Flex & Fatigue Resistance

• Increase Tinsel Strength

• Lower Coefcient of Friction

• Increases UV Thermal Stability

• Easier Machining Abilities

ENHANCEMENT B offers additional emphasis, over ENHANCEMENT A, on the material’s physical

properties to help reduce noise and squeaking; also with increasing ease of movement and overall partlife.

For additional information, please contact Columbia Industrial Products directly.


CIP Enhancement A & B



CIP Series 111

CIP 111 is manufactured from medium weave polyester fabric with excellent mechanical

strength. The lubrication additive is Graphite. The resin is polyester.

Applications

Use CIP 111 for general purpose bearing and wear pad applications, conveyor chain guides,

wear rings, screw conveyor hanger bearings and thrust washers.

Physical and Mechanical Properties (dry running)

Tensile Strength 9,500 psi

Compressive Strength

Normal 35,000 psi

Maximum (Breaking) 50,000 psi

Compressive Strength(parallel) 13,500 psi

Hardness Rockwell M 100

Density .045 lbs/in3

Water Absorption <.1% of wall thk

Operating Temperature Range -40° to 200° F

Tests were performed on sheet material.


CIP Material Grades



CIP Series 121


strength. The lubrication additive is Moly. The resin is polyester.

Applications


screw conveyor hanger bearings and wet installations.




Normal 35,000 psi









CIP Material Grades



CIP Series 131


strength. The lubrication additive is PTFE. The resin is polyester.

Applications


hydraulic wear rings and wet installations.




Normal 35,000 psi









CIP Material Grades



CIP Series 151A

CIP 151A is manufactured from medium weave polyester fabric with excellent mechanical

strength. The lubrication additives are Moly and PTFE for reduced friction. The resin is poly-

ester. Enhancement A has been added to increase performance in strength, wear and abrasion.

Applications

Use CIP 151A for general purpose bearing and wear pad applications, conveyor chain guides,

screw conveyor hanger bearings, thrust washers and wet applications.




Normal 35,000 psi









CIP Material Grades



Machining - Oct. 2010 1

Machining CIP Composites

CIP Composite materials are easily machined by using conventional tooling and methods. You

can use the same methods as you would for Aluminum or Brass.

CIP Composites are machined dry. Dust mask and or work area air suction is suggested.

For lathe work, carbide or diamond tipped tools can be used to generate a ne surface nish.

Diamond tool tips do not produce as much heat when cutting and are suggested for best results.

CIP Composites are 100% bearing material with no llers.

To achieve a ne nish us 3M Scotch-Brite Finishing Flap Brush Grade 5A VFN #01162.

Cutting Angles of Turning

Top Rake 0° to 6°

Side Rake 5° to 8°

Front Rake 4°

to 5°

Speeds for Cutting

Normal for surface nish 22 to 26 feet/second

6.71 to 7.92 meter/second

Speeds for Feed

First pass/roughing .015 to .035 inches per revolution

.38 to .89 mm per revolution

Last pass/nishing .010 to .015 inches per revolution

.25 to .38 mm per revolution



MSDS - Oct. 2010 1

Material Safety Data SheetPage: 1 of 4

Prepared: 8 March 2000

MATERIAL SAFETY DATA SHEET

CHEMICAL PRODUCT AND COMPANY INFORMATION

TRADE NAME: Fiber Reinforced Thermosetting Laminate

MANUFACTURER: Columbia Industrial Products

29538 Airport Road

Eugene, Oregon 97402

EMERGENCY PHONE: 1-800-998-6822

SECTION I - HAZARDOUS INGREDIENTS

MATERIAL CAS NO. PERMISSIBLE AIR LEVEL

ACGIH OSHA

Resin mixture with the following:

Graphite 7782-42-5 2 mg/M3* 5 mg/M3*

Molybdenum Disulde 1317-33-5 10 mg/M3* 10 mg/M3*

Polytetrauoroethylene 9002-84-0 NA NA*Respirable dust

Other ingredients are considered Trade Secrets as stated in OAR

437-155-035/1926.69(1) in the Hazard Communication Rules book

published by the Oregon Department of Insurance and Finance

Accident Prevention Division.

Access to trade secret chemicals identied will be provided to

Health professionals who provide occupational health services

to employees. (437-155-035(2)/1926.59(1) (2) & (3).

The cured product is dened by OSHA as an “article”“which is formed to a specic shape or design during manufacture”

“which has end use function dependant upon its shape or design”

...does not pose a physical hazard/health risk”

This product is completely non-toxic in its solid form. This MSDS is being provided for customers who mightotherwise machine, cut, or burn this material (See Section III).



SECTION II - PHYSICAL & CHEMICAL DATA

Physical State: Solid Shape: Varies

Specic Gravity: .045 #/cu in Odor: No odor

Appearance: White to Grey Solubility in Water: Insoluble

SECTION III - FIRE, REACTIVITY & EXPLOSION DATA

Flash Point: NA

Extinguishing Media: Water

Flammable Limit: NA

Special Fire Fighting Procedures: None

Unusual Fire and Explosion Hazards: None

Stability: Stable

Incompatibility (Materials to Avoid) Strong Alkalis

Hazardous Decomposition Products: None

Hazardous Polymerization: Will not Occur

Conditions to Avoid: Excessive Heat

Cutting, grinding, burning:

Perform machine operations in a well ventilated area.

Mill or machine cured product dry without coolant with tungsten carbide tipped tools.

Unusual re and explosion hazards (Hazardous combustion products):

TOXIC FLUORINE COMPOUNDS, CO, CO2, and NO

2, can be released when involved in re.

Avoid concentrations of airborne dust particulate that can develop into an explosive condition.

Fire Fighting Procedures:

Extinguishing media: Use dry chemical, foam, or CO2, or water spray.

Emergency special equipment required:

Wear a NIOSH approved self-contained breathing apparatus (SCBA).

The solid form is stable and non-reactive except when exposed to strong alkalis.

MSDS - Oct. 2010 2

Material Safety Data Sheet



SECTION IV - HEALTH HAZARD DATA

General:

Toxicological information is not available for this composite. This health assessment is based on theinformation available for the components involved in this “Fiber Reinforced Thermosetting Laminate”.

Graphite Powder:

Acute exposure: High concentrations of graphite dusts may be irritating to the eyes, skin, mucousmembranes and respiratory tract.

Chronic exposure: Inhalations of high concentration of graphite dusts over prolonged periods of timemay cause pneumoconiosis. Symptoms may include cough, shortness of breath, and a decrease in pulmonary function. Pre-existing pulmonary disorders may be aggravated by prolonged exposure of highconcentrations of graphite dust.

Molybdenum Disulde:

References do not report ill health effects as a result of acute or chronic exposure. Molybdenum Disulde isa naturally occurring compound.

Polytetrauoroethylene (PTFE):

Warning: Heating this material above 500° F can produce harmful fumes - toxic gases can be formed.

NOTE: Inhaling fumes of decomposition products can cause temporary inuenza-like symptoms describedas “Polymer Fume Fever” and may include fever, cough, and malaise. No toxic effects are known to beassociated with inhalation or ingestion of dusts.

SECTION V - PRIMARY ROUTES OF ENTRY

Airborne particles when machining and sanding may causeirritation. See Section IX for protection

SECTION VI - PERMISSIBLE EXPOSURE LIMITS

No exposure limits are exhibited by the cured product in its stable form

SECTION VII - CANCER HAZARD

NO: X . This product’s ingredients are not found in the list below

Yes: Federal OSHO___ NTP___ IARC___ APD___

MSDS - Oct. 2010 3




SECTION VIII - PRECAUTIONS, SPILLS

Shipping Information: None

Precautions for handling & storing: Store in cool location.Other Precautions: Avoid contact with excessive heat and strong alkalis

Action if released or spilled: .

Large accumulations cuttings and grindings should be vacuumed in order to minimize dust generationand recovery for proper disposal. This residual material is NOT a RCRA hazardous waste (40CFR 261.). Dispose of solid waste material in accordance with applicable Federal, State and Localregulations. DO NOT incinerate. Disposal in an EPA approved landll is recommended. Keep all products out of sewers and public waters.

SECTION IX - CONTROLS, PROTECTION

Precautions During Use: None

Ventilation & Engineering Controls: Local dust extraction while machining

Respiratory Protection: Non-Toxic particle face mask when machining

Protective Gloves & Cloths: Not Required

Eye & Face Protection: Safety Glasses when cutting

Other Protective Equipment: Not Required

SECTION X - FIRST AID & EMERGENCY PROCEDURES

If irritation of the eyes, nose, or respiratory tract occurs, remove from exposure, and call a physician.

Eyes: Use eye wash with water for at least fteen minutes.

Inhalation: Remove to fresh air

Ingestion: Seek medical attention

Skin: Wash with mild soap and warm water if redness, itching or a burning sensation develops. In theevent of thermal burns, cool with water and seek medical attention.

SECTION XI - ENVIRONMENTAL REQUIREMENTS

Molybdenum Disulde - Was reported on the initial EPA TSCA inventory.

PTFE Resin - All ingredients appear on the EPA TSCA inventory. SECTION XII - ADDITIONAL COMMENTS INFORMATION

The data in this MSDS relates only to the cured product designated herein and does not relate to its use incombination with any other material or process. Since the use of this information and the conditions of useof the product are not within the control of the manufacturer, it is the consumers obligation to determinethe conditions and its safe use. Although the manufacturer believes the statements, technical informationand recommendations contained herein are true and correct, they are given without warranty or guaranteeof any kind, express or implied, and we assume no responsibility for any loss, damage, or expense, direct or consequential, arising out its use/misuse.

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