slideway coatings - skc gleittechnik · 7 slideway coatings slideway coatings skc slideway coatings...

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7 Slideway Coatings Slideway Coatings SKC slideway coatings are used for the production of guideways and sliding sur- faces. Originally developed to be used for machine- tools, today, they are ap- plied for industries being most different from each other as e. g. construction of heavy machinery or of printing machines, they even found entry in optical industry. Apart from the optimal technical properties, for- ming-to-size technique is of- fering a great variety of al- ternatives for a cost-saving production of surfaces in most different designs. Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SKC 60 C 60 C 60 C 60 C 60 standard type application by injection Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SKC 62 C 62 C 62 C 62 C 62 low viscosity application by injection Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SKC 63 C 63 C 63 C 63 C 63 standard type application by spatula Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SKC 63 R C 63 R C 63 R C 63 R C 63 R fast-hardening repair compound application by spatula Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SKC 3 C 3 C 3 C 3 C 3 high loading capacity application by spatula Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SKC 400 ELF C 400 ELF C 400 ELF C 400 ELF C 400 ELF PTFE-slideway coating application by spatula or injection Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SK Slideway Coating SKC 600 C 600 C 600 C 600 C 600 PTFE-slideway coating application by spatula or injection Slideway coating SK Slideway coating SK Slideway coating SK Slideway coating SK Slideway coating SKC 90 C 90 C 90 C 90 C 90 standard type pouring method Advantages high accuracy anti-stick-slip- behaviour very high wear resistance high damping high accuracy to size excellent adhesion properties displayed un- der emergency conditions cost-saving forming-to- size technique interchangeability when forming from a master Fields of applicaton machine tools forming machines sheet-metal working machines printing machines paper machines special machinery measuring machines plastic machines optical appliances machine overhauling handling devices pumps hydraulic tools toolings hydrostatic guideway systems aerostatic guideway systems V V V V V V V V V V V V V V V V V V V V V V V V V 7 E1.10

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Page 1: Slideway Coatings - SKC Gleittechnik · 7 Slideway Coatings Slideway Coatings SKC slideway coatings are used for the production of guideways and sliding sur-faces. Originally developed

7

Slideway Coatings

Slideway Coatings

SKC slideway coatings areused for the production ofguideways and sliding sur-faces. Originally developedto be used for machine-tools, today, they are ap-plied for industries beingmost different from eachother as e. g. constructionof heavy machinery or ofprinting machines, they evenfound entry in opticalindustry.

Apart from the optimaltechnical properties, for-ming-to-size technique is of-fering a great variety of al-ternatives for a cost-savingproduction of surfaces inmost different designs.

Slideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKC 60C 60C 60C 60C 60standard type

application by injection

Slideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKC 62C 62C 62C 62C 62low viscosity

application by injection

Slideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKC 63C 63C 63C 63C 63standard type

application by spatula

Slideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKC 63 RC 63 RC 63 RC 63 RC 63 Rfast-hardening repair compound

application by spatula

Slideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKC 3C 3C 3C 3C 3high loading capacity

application by spatula

Slideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKC 400 ELFC 400 ELFC 400 ELFC 400 ELFC 400 ELFPTFE-slideway coating

application by spatula or injection

Slideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKSlideway Coating SKC 600C 600C 600C 600C 600PTFE-slideway coating

application by spatula or injection

Slideway coating SKSlideway coating SKSlideway coating SKSlideway coating SKSlideway coating SKC 90C 90C 90C 90C 90standard type

pouring method

Advantageshigh accuracyanti-stick-slip-behaviourvery high wear resistancehigh dampinghigh accuracy to sizeexcellent adhesionproperties displayed un-der emergency conditionscost-saving forming-to-size techniqueinterchangeability whenforming from a master

Fields of applicatonmachine toolsforming machinessheet-metal workingmachinesprinting machinespaper machinesspecial machinerymeasuring machinesplastic machinesoptical appliancesmachine overhaulinghandling devicespumpshydraulic toolstoolingshydrostatic guideway systemsaerostatic guideway systems

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Page 2: Slideway Coatings - SKC Gleittechnik · 7 Slideway Coatings Slideway Coatings SKC slideway coatings are used for the production of guideways and sliding sur-faces. Originally developed

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Slideway Coatings • Diagramme of Frictional Characteristics

GG 25 - GG 25p = 10 N/cm²

SKC 3 - GG 25p = 10 N/cm²

SKC 60 - GG 25p = 10 N/cm²

10-6 10-5 10-4 10-3 10-2 10-1 1 10 m/min

Diagramme of Frictional CharacteristicsSKC 3 / SKC 60

0

0,10

0,05

0,15

0,20

0,25

0,30

f0 fv

boundary conditions mixed conditions hydrodynamic frictionof friction of friction

sliding speed

Lubricant:Shell Tonna T 68

coef

fici

ent

of f

rict

ion

The diagramme of fricitonal charac-teristics shows a comparison of thefrictional characteristics of SKC 3 -GG 25 (grey cast) and SKC 60 - GG25 to the pairing GG 25 - GG 25.The advantages of the SKC slidewaycoatings are evident from the follo-wing facts, which are brought out bythe graph:1. The static friction fo is very low, itis about 1/7 of the value of adherentfriction of GG 25 - GG 25 pairings.Corespondingly, the starting forcesand the amount of elastic prestres-sings which the drives generate untilstarting, are low.2. The frictional characteristic ofmotion, i. e. the kinetic friction, initi-ally rises with increasing sliding

speed and will then drop again,when the hydro-dynamic lubricatingfilm is built up. The influence of dif-ferent slide-pairings as, e. g. SKC-cast / cast hardened / steel and steelhardened on the frictional characte-ristics can be ignored.When positioning components, theincrease of the frictional functionavoids the undesired, jerky stress-relief of the drive elements after thestart, and allows exact feed in mic-rons. On the reduction of the sli-ding speed to a standstill, and theend of a feed, the frictional functiondeclines. Thus, a high stress-relief ofthe drive elements is achieved, andan undesired stick-slip, caused byrelief of stresses under the influenceof shocks and of fluctuations of thecutting force are avoided.When machine elements are slidingat low speed - in the range ofboundary conditions - the increaseof the frictional function generate adamping of the sliding process, thusavoiding the undesired stick-slip ef-fect. In contrast to this, the decrea-sing frictional function of other pai-rings of sliding materials leads to aninstability of the sliding process andto stick-slip phenomena.3. The amount of the friction coef-ficient is not only dependent on thepairing. Using an adequate lubricantis also of importance. Apart fromtheir good tribological properties,modern bedway oils also offer anexcellent behaviour of de-emulsifi-cation. If lubricant penetrates intothe guideway gap, the media willnot get mixed; therefore, in normalcase, difficulties can be avoided. Im-peccable lubrication is the only war-ranty for the total function of high-quality machines.

Page 3: Slideway Coatings - SKC Gleittechnik · 7 Slideway Coatings Slideway Coatings SKC slideway coatings are used for the production of guideways and sliding sur-faces. Originally developed

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Slideway Coatings - Characteristics

SKC Slideway Coatings - Characteristics

These statements arebased on practicalexperiences havingbeen won over deca-des and on a greatvariety of researchescarried out at techni-cal universities and byrenowned SKC users.

Anti-stick-slip behaviourAnti-stick-slip behaviourAnti-stick-slip behaviourAnti-stick-slip behaviourAnti-stick-slip behaviour

Even under high area loads, SKCslideway coatings offer a jerk-freestarting and smooth movement. Mi-nimum feed (in the range of mic-rons) and a very precise positioningare achieved by SKC-coated guide-ways, if an adequate drive, an ade-quate lubricating system and lubri-cant are used. This behaviour is ob-tained by the most salient of the po-sitive properties: the static friction fois smaller than the kinetic friction fv.

RRRRResistance to wearesistance to wearesistance to wearesistance to wearesistance to wear

The excellent properties of the SKCcompounds minimize wear of theslideway coating and the opposingguide surface. The readiness withwhich it embeds foreign bodies of-fers an additional and an effectiveprotection against scoring.

FFFFForming exactly to size andorming exactly to size andorming exactly to size andorming exactly to size andorming exactly to size andat low costat low costat low costat low costat low cost

SKC slideway coatings harden with-out any technically relevant shrin-kage, therefore the accuracy of thesurface to be formed is truly repro-duced on the SKC antifriction coa-ting. So, in most cases, a subse-quent and costly mechanical machi-ning is avoided, as the lubricationgrooves can be formed simultane-ously.

Dimensional stabilityDimensional stabilityDimensional stabilityDimensional stabilityDimensional stability

In contrast to many other synthetics,SKC slideway coatings are scarcelyeffected by deformation under load,in particular, under the influence ofheat (see tech. data).

DampingDampingDampingDampingDamping

The high accuracy of SKC-coatedguideways and the technologicalproperties of the slideway coatingallow the minimum of guiding tole-rance. The excellent damping beha-viour of slideways, e. g. comparedto roller-type guideways is thereforeremarkably improved. By the incre-asing frictional function in theboundary area, and into the direc-tion of motion, damping is given.The dynamic rigidity of themachines is improved.

Safety and reliabilitySafety and reliabilitySafety and reliabilitySafety and reliabilitySafety and reliability

The excellent properties underemergency conditions of the SKCslideway coatings avoid high wear,even under unfavourable conditions,such as inadequate lubrication. SKC-coated guideways do not “seize”.

Excellent adhesionExcellent adhesionExcellent adhesionExcellent adhesionExcellent adhesion

SKC slideway coatings adhere excel-lently on cleaned metallic surfaces,and also on existing SKC layers.Correction of damage or of machi-ning errors on SKC slideway coa-tings can be done easily. Even oncomponents of machines made ofsolventless polymerisable resinouscompound or cement-bound con-crete, SKC slideway coatings haveoutstanding adhesion characteristics.

Chemical PChemical PChemical PChemical PChemical Propertiesropertiesropertiesropertiesroperties

SKC compounds are resistant towater, sea water, mineral and syn-thetic oils, weak acids and caustics,gasoline and alcohol.They are not resistant to acetone,benzene, methanole, phenoles andcresoles (under permanent load),and to solvents (under a longer-la-sting influence).Any particulars as far as chemical re-sistance is concerned have to beseen under a certain reservation, asparameters like temperature, timeof action and state of hardening ofthe compounds are of importance.If there is any doubt, we recom-mend to provide specific storingtests.In cases of long-term influence un-der watery solvents, as well as bydepositing of oxydes, fission andmetabolic products (especially fromwater-mixable coolants/lubricants)dimensional variations of some mic-rons might occur.Upon request, we are well prepa-red to send you detailed and rele-vant information.

Page 4: Slideway Coatings - SKC Gleittechnik · 7 Slideway Coatings Slideway Coatings SKC slideway coatings are used for the production of guideways and sliding sur-faces. Originally developed

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Slideway Coatings • Technical Data

Technical DataSlideway Coatings

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SKC 3SKC 3SKC 3SKC 3SKC 3 SKC 400 ELFSKC 400 ELFSKC 400 ELFSKC 400 ELFSKC 400 ELF SKC 60SKC 60SKC 60SKC 60SKC 60 SKC 62SKC 62SKC 62SKC 62SKC 62

Specific weight [kg/dm³] 1.8 1.4 1.6 1.5

Mixing ratio resin : hardener 100:8.0 100:10.3 100:9.5 100:9.9

Safe surface load, dynamic [N/mm²] 15 2 5 5

Safe surface load, static [N/mm²] 100 10 50 50

Modulus of elasticity [N/mm²] 6190 2920 4850 4770

Hardness [Shore D] 83,5 n. b. 82 80

Coefficient of friction f0 as per type of oil < 0.10 < 0.06 < 0.08 < 0.08

Maximum operating temperature [°C] 80 (short-time100)

Heat-exchange coefficient [K-1] ~ 30 x 10-6

Heat conductance [W/mK] 0.5-0.8

Volume resistance [Ωcm] ~ 1 x 1017

Dielectric coefficient ~ 4

Dielectric strength [kV] ~ 10 (at 2.5-3 mm thickness of layer)

Minimum thickness of layer, approx. [mm] 1.5 1.5 2.0 1.5

Shrinkage during hardening [%] < 0.1

Quantity required volume [cm³] x Fm equals quantity [g]

Factor Fm * spatula method 3 3 - -

Factor Fm * injection/pouring method - 2 2 2

Time of application at 20 °C, approx. [min] ** 45 45 30 30

Time before separation at 20 °C [h] 12-16 18-22 12-16 12-16

Hardening time at 20 °C [h] 16-22 22-30 16-22 16-22

Storing life at approx. 20 °C, dry conditions 12 month

Available ready-to-use packings see order details

* The factor Fm contains the specific weight and a safety factor.** The time of application is strongly depending on the ambient temperature and the mixing process. Even in cases of big acclomerations of

the compound (e. g. in cartridge or can) the time of application can become widely shorter.

Page 5: Slideway Coatings - SKC Gleittechnik · 7 Slideway Coatings Slideway Coatings SKC slideway coatings are used for the production of guideways and sliding sur-faces. Originally developed

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Slideway Coatings • Technical Data

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SKC 63SKC 63SKC 63SKC 63SKC 63 SKC 63 RSKC 63 RSKC 63 RSKC 63 RSKC 63 R SKC 90SKC 90SKC 90SKC 90SKC 90 SKC 600SKC 600SKC 600SKC 600SKC 600

Specific weight [kg/dm³] 1.7 1.6 1.4 1.2

Mixing ratio resin : hardener 100:11.3 100:8.4 100:12.6 100:12.0

Safe surface load, dynamic [N/mm²] 5 5 4 2

Safe surface load, static [N/mm²] 50 50 30 10

Modulus of elasticity [N/mm²] 5020 4850 4200 2920

Hardness [Shore D] 82 85 80 n. b.

Coefficient of friction f0 as per type of oil < 0.08

Maximum operating temperature [°C] 80 (short-time 100)

Heat-exchange coefficient [K-1] ~ 30 x 10-6

Heat conductance [W/mK] 0.5-0.8

Volume resistance [Ωcm] ~ 1 x 1017

Dielectric constant ~ 4

Dielectric strength [kV] 10 (at 2.5-3 mm thickness of layer)

Minimum thickness of layer, approx. [mm] 1.5 1.0 2.0 1,5

Shrinkage during hardening [%] < 0.1

Quantity required volume [cm³] x Fm equals quantity [g]

Factor Fm * spatula method 3 3 - 3

Factor Fm * injection/pouring method - - 2 2

Time of application at 20 °C, approx. [min] ** 30 15 45 45

Time before separation at 20 °C [h] 12-16 1,5 18-22 18-22

Hardening time at 20 °C [h] 16-22 4 22-30 22-30

Storing life at approx. 20 °C, dry conditions 12 month 12 month 9 month 12 month

Available ready-to-use packings see order details

The above details are to our best knowledge. We cannot accept responsibility in individual cases as the way in which the mate-rial is prepared and handled is outside our control. Due to the manifold conditions of production, operating and application,every user has to check by himself the suitability of the product for his specific purpose of application. The specifications given inthis brochure are not to be understood as an assured property.

Page 6: Slideway Coatings - SKC Gleittechnik · 7 Slideway Coatings Slideway Coatings SKC slideway coatings are used for the production of guideways and sliding sur-faces. Originally developed

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Slideway Coatings • Diagrams

Diagrams

Coefficients of friction: Standard series oils VG 220Coefficients of friction: Standard series oils VG 220Coefficients of friction: Standard series oils VG 220Coefficients of friction: Standard series oils VG 220Coefficients of friction: Standard series oils VG 220 Sequence of hardening of various SKSequence of hardening of various SKSequence of hardening of various SKSequence of hardening of various SKSequence of hardening of various SKC coatingsC coatingsC coatingsC coatingsC coatings

Aging SKAging SKAging SKAging SKAging SKC 60 - Development TgC 60 - Development TgC 60 - Development TgC 60 - Development TgC 60 - Development Tg

Behaviour of deformationBehaviour of deformationBehaviour of deformationBehaviour of deformationBehaviour of deformationWWWWWarming-up wear of various materialsarming-up wear of various materialsarming-up wear of various materialsarming-up wear of various materialsarming-up wear of various materials(extract from a test of a renowned German machine-tool manufacturer)

0,5 1 1,5 2 2,50

1

2

3

4

5

6

7

compressive load per unit area [N/mm²] compressive load per unit area [N/mm²] compressive load per unit area [N/mm²] compressive load per unit area [N/mm²] compressive load per unit area [N/mm²]

Def

orm

atio

n [µ

m]

Def

orm

atio

n [µ

m]

Def

orm

atio

n [µ

m]

Def

orm

atio

n [µ

m]

Def

orm

atio

n [µ

m]

PTFE, bronze-filledPTFE, bronze-filledPTFE, bronze-filledPTFE, bronze-filledPTFE, bronze-filled(circumferential-ground)(circumferential-ground)(circumferential-ground)(circumferential-ground)(circumferential-ground)

SKSKSKSKSKCCCCC(formed to size)(formed to size)(formed to size)(formed to size)(formed to size)

grey cast iron 25grey cast iron 25grey cast iron 25grey cast iron 25grey cast iron 25(face-milled)(face-milled)(face-milled)(face-milled)(face-milled)

grey cast iron 25grey cast iron 25grey cast iron 25grey cast iron 25grey cast iron 25(circumferential-ground)(circumferential-ground)(circumferential-ground)(circumferential-ground)(circumferential-ground)

PTFEPTFEPTFEPTFEPTFE(circumferential-(circumferential-(circumferential-(circumferential-(circumferential-

ground)ground)ground)ground)ground)

0 2 4 6 8 10 12 14 16 18 20 22 240

10

20

30

40

50

60

70

80

90

100

time [h] time [h] time [h] time [h] time [h]

hard

enin

g [%

] ha

rden

ing

[%]

hard

enin

g [%

] ha

rden

ing

[%]

hard

enin

g [%

]

SKSKSKSKSKC 63 RC 63 RC 63 RC 63 RC 63 R

SKSKSKSKSKC 60C 60C 60C 60C 60SKSKSKSKSKC 3C 3C 3C 3C 3SKSKSKSKSKC 400 ELFC 400 ELFC 400 ELFC 400 ELFC 400 ELF

SKSKSKSKSKC 90C 90C 90C 90C 90

0 1 2 3 4 5 6 7 820

40

60

80

100

time [h] time [h] time [h] time [h] time [h]

glas

s tr

ansit

ion

poin

t Tg

[°C

] gl

ass

tran

sitio

n po

int T

g [°

C]

glas

s tr

ansit

ion

poin

t Tg

[°C

] gl

ass

tran

sitio

n po

int T

g [°

C]

glas

s tr

ansit

ion

poin

t Tg

[°C

]

80 ° C80 ° C80 ° C80 ° C80 ° C

60 ° C60 ° C60 ° C60 ° C60 ° C

40 ° C40 ° C40 ° C40 ° C40 ° C

room temperatureroom temperatureroom temperatureroom temperatureroom temperature

1

2

3

4

5

6

7

8

9

10

11

12

0 0,05 0,1 0,15 0,2 0,25 0,3

coefficient of friction fcoefficient of friction fcoefficient of friction fcoefficient of friction fcoefficient of friction f00000

oils

oils

oils

oils

oils

grey cast iron-grey cast irongrey cast iron-grey cast irongrey cast iron-grey cast irongrey cast iron-grey cast irongrey cast iron-grey cast iron

SKSKSKSKSKC 3-grey cast ironC 3-grey cast ironC 3-grey cast ironC 3-grey cast ironC 3-grey cast iron

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0 5 10 15 20 250

5

10

15

route [km] route [km] route [km] route [km] route [km]

wea

r [µ

m]

wea

r [µ

m]

wea

r [µ

m]

wea

r [µ

m]

wea

r [µ

m]

PTFE, bronze-filledPTFE, bronze-filledPTFE, bronze-filledPTFE, bronze-filledPTFE, bronze-filled(scraped)(scraped)(scraped)(scraped)(scraped)

SKSKSKSKSKC 63C 63C 63C 63C 63(scraped)(scraped)(scraped)(scraped)(scraped)

SKSKSKSKSKC 3C 3C 3C 3C 3(scraped)(scraped)(scraped)(scraped)(scraped)

countercountercountercountercounter-guideway: grey cast iron 25 (face milled)-guideway: grey cast iron 25 (face milled)-guideway: grey cast iron 25 (face milled)-guideway: grey cast iron 25 (face milled)-guideway: grey cast iron 25 (face milled)sliding speed v = 30 m/minsliding speed v = 30 m/minsliding speed v = 30 m/minsliding speed v = 30 m/minsliding speed v = 30 m/minsurface load p = 50 N/cm²surface load p = 50 N/cm²surface load p = 50 N/cm²surface load p = 50 N/cm²surface load p = 50 N/cm²lubrication: Shell C22, unpressurizedlubrication: Shell C22, unpressurizedlubrication: Shell C22, unpressurizedlubrication: Shell C22, unpressurizedlubrication: Shell C22, unpressurized

countercountercountercountercounter-guideway: grey cast iron 25-guideway: grey cast iron 25-guideway: grey cast iron 25-guideway: grey cast iron 25-guideway: grey cast iron 25(circumferential grinding)(circumferential grinding)(circumferential grinding)(circumferential grinding)(circumferential grinding)

Page 7: Slideway Coatings - SKC Gleittechnik · 7 Slideway Coatings Slideway Coatings SKC slideway coatings are used for the production of guideways and sliding sur-faces. Originally developed

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Slideway Coatings • Guidelines for Application

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Guidelines for ApplicationSlideway Coatings

PPPPPreparationreparationreparationreparationreparation

Roughening of the surface to becoatedTo improve adhesion, the guide sur-face to be coated has to be roughe-ned. The peak-to-valley heightshould be about 0.5 mm(Rt=500 µm). Roughening can beprovided by rough-planing, rough-milling, by cutter or by bore hole,i.e. by turning a thread. Sandbla-sting, using hard and sharp grains(blasting medium: a high-furnaceslag G 77, grain 0.6-1.2 mm) offersan especially good adhesion surface.In case of all these processes, carehas to be taken, that the surface willnot be compressed, but will becracked.

Cleaning of the surface to be coatedThe components to be coated haveto be cleaned thoroughly. For pre-cleaning various cleansing agents canbe used.We are at your service to provideyou with information on a suitablecleansing agent.The surfaces to be coated have tobe free from oil, grease, dust, rust,scale and protective paint. In case ofa mineral cast, it is necessary to re-move the layer of separating wax ortreatments. For the final cleaning be-fore coating, preferably acetone

should be used. Care has to be ta-ken when compressed air is usedfor dry-blowing of the adhesion sur-faces, because it often contains oilwhich might affect adhesion.

Counter guideway and forming-to-size surfaceSKC coatings can be formed to sizefrom all kinds of counter guideways,from devices (masters), from thecounter surface, or - for instance -from gauge plates or templates.When forming, the roughness of thecounter guideway should not ex-ceed Ra = 2.5 µm. The countersurfaces can be ground, fine-milled,broad-smoothened planed or fine-turned.

Releasing compoundsThe surfaces from which forming-to-size is provided, are to be trea-ted with a releasing compound. De-pending on the specific case, variousreleasing compounds are available.Each to type, they are applied with acleaning rag or a brush or they aresprayed on. After application and fora short time, the releasing com-pound layer is left to dry and thencarefully polished with a soft cloth.Please, see chapter ‘Accessories’ fora description of the various releasingcompounds.Before coating, all areas on whichcompound might escape during theforming process and where it has tobe removed after hardening, arealso to be treated with a releasingcompound.About 1 kg of releasing compoundis required for the application of 10kg of slideway coating.

Formable oil groovesThe forming-to-size technique al-lows a simultaneous moulding of theoil grooves. The pre-fabricatedshapes of the oil grooves are spray-ed with an adhesive spray and adhe-red on the forming surface. It is im-

portant to spray only a thin layer ofthe adhesive and to let it ventilateafter spraying. For precise informati-on, please, see the instructions ofuse on the adhesive spray. Theshapes of the oil grooves have to bepressed on tightly and then to betreated with a releasing compound.After hardening of the compoundthe shapes of the oil grooves can beremoved from the compound. Theoil groove itself can be lifted at itsend by means of a pointed toolingand be withdrawn by hand.All application techniques allow aforming-to-size of the oil grooves.For shapes and dimensions, please,see chapter ‘Accessories’.

Calculation of quantityFor application by spatula, the volu-me of the coating groove - in cm3 -is multiplied by factor Fm. This givesthe required quantity of the com-pound in grammes. Factor Fm allowsfor the specific weight as well as asafety margin and depends on thecompound to be used and the ap-plication. The applicable value canbe seen from the technical data.

Removal of the coated componentAfter hardening, the component canbe lifted off. In case of very bigworkpieces, additional devicesshould be used to relieve the crane,as e.g. pressure screws or a winch.Before lifting off, and if possible, thecomponent should be loosened inthe direction of motion of the guide-way.

Example for roughening of the surface to becoated by planing (lh.) and milling (rh.)

Example of calculation for injection method

material: SKC 60 (Fm=2):guideway: length 800 mm, width 50 mm,

thickness of layer 2,5 mm

80 cm x 5 cm x 0,25 cm x 2 g/cm3 = 200 g

TTTTTime of applica-ime of applica-ime of applica-ime of applica-ime of applica-tion, time beforetion, time beforetion, time beforetion, time beforetion, time beforeseparat ion andseparat ion andseparat ion andseparat ion andseparat ion andhardening time:hardening time:hardening time:hardening time:hardening time:see techn ica lsee techn ica lsee techn ica lsee techn ica lsee techn ica ldata.data.data.data.data.

!

Page 8: Slideway Coatings - SKC Gleittechnik · 7 Slideway Coatings Slideway Coatings SKC slideway coatings are used for the production of guideways and sliding sur-faces. Originally developed

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Slideway Coatings • Guidelines for Application

Retouching workAt the front, the edges of squeezedout material have to be removedusing either a portable grinding ma-chine or a coarse linen cloth. Lateraledges of squeezed out material areto be traced and to be cut off with aflat chisel.

Flaws, pits or chipped partsof the coating can easily berepaired. In this area, the

slideway coating will be roughened,decreased and the flaw to be filledin with SKC coating. For quick re-pairs, SKC 63 R is available. Flawshaving been repaired with this com-pound can be treated already after3-4 hours. If necessary, all the SKCslideway coatings can be machinedmechanically (see also the table withthe empirical values).For all the mechanical processes,care has to be taken that no heatingof the surface of the coating will oc-cur.Bore holes for lubricants are to beopened by boring from the coatingside to prevent an escape of thecoating.

Application by spatulaApplication by spatulaApplication by spatulaApplication by spatulaApplication by spatula

PositioningThe workpiece to be coated is posi-tioned at its moulding surface onsetting screws, feelers, stops, and bymeans of clock gauges or water le-vels so that is dimensionally alignedto the surfaces of reference. As theworkpiece has to be removed in or-der to apply the SKC slideway coa-ting, the positioning points have tobe marked.

MixingSKC slideway coatings are availablein various ready-for-use packs con-taining epoxy resin and hardenerprecisely proportioned to eachother in weight. So, an additionalweighing is not required and shouldbe avoided. For mixing, the epoxy-resin compound has to be loosenedwith a spatula from the tin wall andthe tin base, the hardener is to bepoured in and to be mixed in byhand. Subsequently, at about 400rpm, the two components are to bemixed well with the SKC stirrer

which has to be chucked in a drill-or in an upright drilling machine. Astirring time of 3 minutes has to beobserved. Take care that the stirrerwill not grind at the tin base, asotherwise, the compound will heatup.After mixing, the SKC compoundsapplicable by spatula have to be ta-ken out of the tin immediately andto be spread out on a sheet (see ill.below). By spreading out the com-pound, a certain part of the reactionheat is released, thus increasing thepot life; any air bubbles stirred in arecracked. If the material remains inthe tin, a heat accumulation is crea-ted, which may lead to a short-termhardening. For a quantity of 0.5 kgsof SKC compound applicable byspatula, a sheet measuring about500 x 500 mm should be used.

Application time and temperatureThe application time is dependingon the material to be used. Theright values are shown on the table‘Technical Data’. SKC coatings requi-re an ambient temperature of atleast 18 °C. For the coating process,the workpieces, too, must have thistemperature; if necessary, they areto be heated by radiator.

Application of the coatingBy means of a spatula, the materialis removed from the sheet and app-lied in several thin layers, where thefirst layer has to be pressed carefullyinto the roughening. At the end, thematerial has to be applied somew-hat roof-shaped, so that the com-pound is displaced from the in- tothe outside without any air poc-ketswhen placed against the counter-surface.

!

MethodMethodMethodMethodMethod Data of applicationData of applicationData of applicationData of applicationData of application

Milling cutter head with 4 cutters, PKD (poly-crystaline diamond)cutting speed v ....................... about 130 m/minfeed per tooth fz ..................... 0.08-0.1 mm/cutting toothcutting depth a ....................... 0.1-0.3 mmchip angle γ ............................ axially positive, radially negativefeed speed u .......................... 150-200 mm/minrpm of workpiece n ............... about 500 min-1

Attention: the ‘u’ and ‘n’ values only apply as informative values for acutter diameter of 80 mm with 4 cutters!

feed speed u = fz x z x nfz: feed per cutter in mm/cutting toothz: number of cuttersn: rpm of workpiece in min-1

Grinding silica-carbide wheel36-46 G 8, wet grinding‘Stellram’ wheel42 A 46 H 16 V 24 (A = 50 % natural und 50 % crystal corundum)wet grinding, v = 25-30 m/s‘Naxos’ wheelEKD 36 / 02G / H7 KE 100, wet grinding

Honing type of device ........................ portable honing device AN 815honing oil ............................... standard honing oilhoning stone .......................... 4 stones without guiding

W 47 - J 63 - 772XAttention: After honing, the bore holes have to be cleaned!

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Slideway Coatings • Guidelines for Application

Forming-to-size of the matingcomponentThe workpiece is positioned on themoulding point and lowered to thealigning points (setting screws etc.)which had been marked before. Ex-cess material is squeezed off. Anycorrections within the range ofsome 1/100 mm can still be carriedout into direction of the coating. Inno case shall the mating componentbe lifted, as this would draw in airpockets. Light workpieces are in ad-dition to be loaded with a weight orto be clamped with retainer gibs orscrew clamps. When the aligningpoints are reached, the workpiece isunloaded or respectively unclam-ped.

Injection methodInjection methodInjection methodInjection methodInjection method

PreparationFor an application by injection, thelayer thickness depends on the ma-terial to be used and should beabout 2 mm (please see technicaldata for the minimum layer thick-nesses). Depending on the presssystem which is used on workpieceshaving a coating length of up toabout 1000 mm, the injection borehas to be provided in the centre,thus enabling a uniform distributionof the compound into both direc-tions of the coating gap. In case oflonger pieces, several injection bo-res are required being at a distanceof about 500 mm to each other. Fora vertically arranged coating gap, theinjection bore has to be arranged aslow down as possible.

SealingDepending on the possibilities ofdesign or of the techniques of pro-duction, sealing is carried out bymetallic edges or by foam-rubberstrips.Metallic edges are used as a directsupport, and should be pre-ma-chined exactly, according to the di-mensional requirements. Beforecoating, adhesive-tape strips (e.g.linen-reinforced adhesive tape0.3 mm thick) can be adhered onthose edges free. A subsequent un-dercutting of the compound is notrequired.

When sealing with foam rubber, anoptimal sealing effect is obtainedwhen the profiles are compressedto about 50% of their original thick-ness.

PositioningThe workpiece, cleaned and prepa-red for coating is placed on themoulding surface, which has beentreated with the releasing com-pound, aligned by means of settingscrews or similar devices, and fixed.During injection, the aligned com-ponent has to be kept in position,by means of retainer gibs, screw-clamps, etc. , so that a displacementcaused by the injection pressure, isavoided. In a range of a few 1/100mm a re-adjustment into directionof the coating can be done after in-jection.

MixingSKC slideway coatings are availablein various ready-for-use packs con-taining epoxy resin and hardenerprecisely proportioned to eachother in weight. Therefore theseready-for-use packs should be usedcompletely.For mixing, the epoxy-resin com-pound has to be loosened with aspatula from the tin wall and the tinbase. In case of the low-viscouscompounds SKC 62 and SKC 90,the fillers deposit after a certainstock time and - before adding thehardener - they have to be stirredup thoroughly. For this purpose, theresidue has to be loosened from thetin base and the resin compoundstirred thoroughly until the com-pound is clod-free. Before furtheruse, the resin compound has tocool down to ambient temperature.Then, the hardener is added andcarefully poured in and - for 1 minu-te - mixed by hand intensively withthe resin. Final mixing at about 400rpm with the SKC stirrer which hasto be chucked in a drill- or in an up-right drilling machine. A stirring timeof 3 minutes has to be observed. Aninsufficient mixing of the two com-ponents might cause the risk of softspots.

Systems of presses(see also ‘Accessories’)The coating has to be poured in athin stream onto the wall of thecartridge which should be held in aninclined position. Press the pistoninto the filled cartridge and ventilate.For ventilation, the cartridge has ei-ther to be deformed slightly by de-pressing the piston or providingventilation by adding a thin wire du-ring inserting the piston. Afterwards,the wire has to be removed.Only for cartridges SK500, KK1000:The tip of the thread nipple is to becut off and the nozzle to be reducedto the diameter of injection bore(see chart on right side). Then, thediaphragm inside of the cartridge ispierced from the front through thenipple. Attach nozzle as required.Insert the cartridge into the pressand close the press with the sealingcap. Hold the press vertically up-wards and ventilate it until a smallquantity of compound escapes. Ac-cording to the press system, thecartridge nozzle is to be pressed orscrewed into the the injection boreprovided. Press the coating for jointfaces slowly and continuously intothe gap, until it escapes through theventilation bore at the farthestpoints.

Coating of long workpieces with se-veral injection boresThe coating process is started fromthe central injection bore. Pressingin has to be continued until thecompound escapes from the adja-cent injection bores. Then, removethe press and seal the bore with athread plug. Now, sequence of coa-ting is continued from the boreswhere the compound has escaped.The process is repeated, until thecomplete guideway is filled. Coatingof longer workpieces should be car-ried out simultaneously with twopresses.

Injection borenozzle to be shor-

tened by

Ø 6 0 mmØ 8 12 mmØ 10 25 mmM 8 5 mmM 10 16 mmR ¼“ 36 mm

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PPPPPouring methodouring methodouring methodouring methodouring method

The preparations are correspondingto those of the injection method. Asfilling of the compound into the coa-ting gap is done almost without anypressure, pourable slideway coa-tings can be poured in directly offthe can. A thin jet makes air pocketscrack and escape.In other cases, a filling of the gap isfunctionally made via a hose (PVCtransparent, Øinside 12 x 2 mm).This hose is plugged onto a shortpiece of a pipe having an outsidediameter of 12 mm. The cartridgetogether with the nozzle is then in-serted into the free end of the hose;the cartridge itself will now be filleddirectly off the can. When the com-pound escapes at the control bores,the latter will be closed. As a materi-al reservoir, the filling hose remainsconnected until separation. In caseof horizontal gaps, the filling bore isto be arranged centrally and for ver-tical gaps at the lower end.

Filling of a gap via a hose (pouring method)

Slideway Coatings • Guidelines for Application

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The repairing compound SKC 400 R is usedon the same way as SKC 63 R. The technicaldata are similar to those of SKC 400 ELF.Even with the blue compound SKC 400 ELF,the repairing compound SKC 400 R allows arepair inconspicuous in colour.

Parts by weight for the consumption of smaller quantities of the compounds

Splitting of resin and hardener should be done only by means of a balancehaving an accuracy of reading of 0.1 g!

resin [g] hardener [g]SKC 63 R SKC 400 R

20 1.7 1.830 2.5 2.640 3.3 3.550 4.2 4.4

Repair CoatingsSKC 63 R / SKC 400 R

Information • Repair Coatings

Coatings, applicable by spatula for the repair of blowCoatings, applicable by spatula for the repair of blowCoatings, applicable by spatula for the repair of blowCoatings, applicable by spatula for the repair of blowCoatings, applicable by spatula for the repair of blow-holes,-holes,-holes,-holes,-holes,for instance of inclusions, open spaces or scores.for instance of inclusions, open spaces or scores.for instance of inclusions, open spaces or scores.for instance of inclusions, open spaces or scores.for instance of inclusions, open spaces or scores.

The coatings SKC 63 R andSKC 400 R, applicable by spatula,have been developed for the repairof blow-holes, for instance of inclusi-ons, open spaces or scores.

Before repairing worn-out guideways,the scores have to be milled or grounddown to the exit (‘zero transition’)about 1 mm deep.Using, for instance, a portable drillingmachine with a grinding point, inclu-sions have to be ground or milled so,that the created blow-hole can befilled easily and is free from contami-nations.

In order to reduce re-machining andto press the coating into the scores orinto the inclusions, a guide-bar, groundand pre-treated with a releasing com-pound should be placed or chuckedonto the coated area.Alternatively, or on uneven surfaces,the repaired areas can me masked offwith a smooth adhesive tape, afterthey had been filled out with therepair compound.

The repair compound combines its-elf homogeneously with all the SKCcoatings and adheres excellently onall cleaned and roughened surfaces(e. g. metal, mineral casting etc.).

The hardening time does stronglydepend on the temperature conditi-ons. At room temperatures of 20 °C,the repaired surfaces can be re-scraped 2 hours after the compoundhas been applied.

After hardening, the repaired areascan be treated mechanically (turning,milling, drilling, grinding). In order toequalize small repaired blow-holes,in cases where the surface is exposedto high demands after hardening, afine abrasive cloth (grain size 220)used with machine oil has provensuccess.

If the blow-holes repaired by thatmethod have to be absolutely freefrom inclusions (bearing surface ofsealing rings, general sealing function),then, afetr 8 hours, the surfaces are tobe scanned under appropriate pres-sure with a pointed but not sharpobject, as e. g. a rounded scriber.This method discovers the blow-ho-les sitting under the surface whichthen can be repaired as describedabove.

To be removed!

blow-holes/inclusions/scores

masking bar

SKSKSKSKSKCCCCCSKSKSKSKSKCCCCC

Diagram for the appli-cation of SKC repaircompounds.

The repairing compound SKC 400 R is usedon the same way as SKC 63 R. The technicaldata are similar to those of SKC 400 ELF.Even with the blue compound SKC 400 ELF,the repairing compound SKC 400 R allows arepair inconspicuous in colour.

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Slideway Coatings • Examples of Application

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Examples of Application

ill. 1:Coated hydraulic piston for the table drive of a gui-deway grinding machine (diameter of piston 230mm)

ill. 2:Sleeve guiding

ill. 3:Worm rack, single-thrust bearing

To be removed!

blow-holes/inclusions/scores

masking bar

SKSKSKSKSKCCCCCSKSKSKSKSKCCCCC

ill. 6 and 7:Repair of scores in a metallic guideway - applying repair coating SKC 63 R

ill. 5:compressor screw

ill. 4:Coated slideways and worm rack. Table of a gantry milling machine.

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Slideway coatings • Examples of Application

Examples of Application

ill. 10:half-shell of a laser gun, diam. 550 mm, 1200 mmlong, cylindricity < 15 µm, vacuum channels di-rectly moulded (see also: accessories, groove foil)

ill. 8:Slide of a grinding machine, hydrostatic guiding system, guiding dimensions6000 x 230 mm, direct forming-to-size of hydrostatic pockets

ill. 9:Polymeric concrete-component for demonstrationpurposes with directly moulded V-guides

ill. 11:Hydrostatic bearing ring of a crank-stroke millingmachine with moulded pockets

ill. 12:Coated gibs with directly moulded lubricationgrooves

ill. 13:V-guides of the table of a milling machineFor the separation of the counter guiding of bigcomponents additional means are used (e. g. awinch) to relieve the crane.

ill. 14:Guiding system of a slide

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Slideway coatings • Examples of Application

Example of ApplicationCoating of the Guideways of a Horizontal MillingMachine - Spatula Method

1) This guideway system of the bot-tom slide is consisting of two hori-zontal flat guideways ‘a’, a verticalflat guideway ‘b’, a vertical guidewaywith V-ledge ‘c’ and two retainergibs for cover strips ‘d’ (ill.1).

2) Pre-machining of the surfaces tobe coated is provided by rough-pla-ning or rough-milling to obtain thesurface shown by ill. 2. By rough-milling, a similar surface shall analo-gously be created by circular scores.The theoretical layer thickness overthe score tips shall be at least 1 mm.All counter surfaces used for the for-ming-to-size, which have to be finis-hed and to be optimally aligned, aretreated with a separator and smoo-thened with a soft rag.It is also recommendable to treatthose areas of the free surfaces withthe separator on which - duringmoulding - the compound may es-cape, and wherever possible, toprotect them with an adhesive tape.The preparations of a coating pro-cess do also include determinationof a measuring and aligning methodto produce the layer thickness andthe necessary position of the bot-tom slide, relative to the guidewayof the slide and to the spindle axis.Suitable devices and gauges have tobe at immediate disposal, as duringthe moulding process, the timeavailable to align the bottom slide islimited.

3) After applying by spatula theslideway coating onto the surfaces aand b, the bottom slide will be tur-ned, will be laid on the bottom gui-deways, slowly and as much as pos-sible parallel, and - following thewater levels - it will be alignedexactly into longitudinal and trans-versal direction, e.g. by means ofsetting screws in the thread boresfor the cover gibs (ill. 3). If necessa-

ry, surface b has to be coated in aseparate operation.

4) To verify the rectangular positionof the bottom-slide guiding to theaxis of the spindle, a device asshown by ill. 4 is used. The positionhas to be corrected by means oftwo wedges at the front verticalguideway between bed and bottomslide.Take care, when removing the coa-ting escaped both at the long and atthe front sides. Do not knock it off.In case of a mechanical re-machiningor when correcting by scraping,please follow the application guideli-nes. Turn the bottom slide and posi-tion it onto the bed and verify it asdescribed under 3) and 4).

ill. 1

ill. 2

ill. 3

ill. 4

aa bd d

Apply the slideway coating by spatu-la on the cover gibs d and mountthem.Do not forget the separator on theretainer gibs! After hardening of thecompound, dismantle the cover gibsand machine them as described.Mill in the lubrication grooves and -if required - open by boring anylube-oil bores which might havebeen closed when applying the coa-ting.

Forming-to-size of the guideway ofthe transversal slide or of the spind-le-slide guideway will be carried outanalogously, with reference to thegeometrical assignable values.

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Slideway Coatings • Examples of Application

Example of ApplicationCoating of the Guideways of the Bottom Slideof a Turning Lathe - Spatula Method

ill. 1

b

ill. 3

ill. 2

ill. 4

ill. 5

c da

1) This guideway system of the bot-tom slide is consisting of a V-guidesystem ‘a’, a flat guideway ‘b’ andtwo retainer gibs ‘c’, ‘d’ (ill.1).

2) Pre-machining of the surfaces tobe coated is provided by rough-pla-ning or rough-milling to obtain thesurface shown by ill. 2. By rough-milling, a similar surface shall analo-gously be created by circular scores.The theoretical layer thickness overthe score tips shall be at least 1 mm.All counter surfaces used for the for-ming-to-size, which have to be finis-hed and to be optimally aligned, aretreated with a separator and smoo-thened with a soft rag. It is also re-commendable to treat those areasof the free surfaces with the separa-tor on which - during moulding -the compound may escape, andwherever possible, to protect themwith an adhesive tape.The preparations of a coating pro-cess do also include determinationof a measuring and aligning methodto produce the layer thickness andthe necessary position of the planeslide relative to the guideway of thebed and to the spindle axis. Suitabledevices and gauges have to be atimmediate disposal, as during themoulding process, the time availableto align the bottom slide is limited.

3) After applying by spatula the anti-friction coating onto the surfaces aand b, the bottom slide will be tur-ned, will be laid on the bottomguideways, slowly and as much aspossible parallel, and - following thewater levels - it will be alignedexactly into longitudinal and trans-versal direction, e.g. by means ofsetting screws in the thread boresfor the cover gibs (ill. 3).

4) To verify the rectangular positionof the plane-slide guiding to the axisof the spindle, a device as shown isused. The position has to be correc-ted by means of two wedges at thefront vertical guideway betweenbed and bottom slide.

After about 24 hours, the bottomslide has to be lifted off and the sur-faces a) and b) to be scraped with 5-8 mm long strokes.

Take care, when removing the coa-ting escaped both at the long and atthe front sides. Do not knock it off.

In case of a mechanical machining orwhen correcting by scraping, pleasefollow the application guidelines.

Turn the bottom slide and position itonto the bed and verify it as descri-bed under 3) and 4).

5) Apply the slideway coating byspatula on the cover gibs c) and d)and mount them.Do not forget the separator on theretainer gibs! After hardening of thecompound, dismantle the cover gibsand re-machine them as described.Mill-in the lubrication grooves and -if required - open by boring anylube-oil bores which might havebeen closed when applying the coa-ting.Forming-to-size of the guideways ofthe longitudinal slide or of the tail-stock slide will be carried out analo-gously, with reference to the geo-metrical assignable values.

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