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Simple repair method for larger diameter bending shaft
In the daily operations of material mixers, crushers, and other machinery within the Construction Materials sector, spindles often become deformed or bent due to the presence of iron and other foreign objects. When a spindle becomes bent, it can be quite challenging to repair it without scrapping or significantly altering its structure. Based on my experiences, I have developed a practical, manual method to correct spindles with diameters exceeding 90 mm. Here's how it works:
(1) First, mount the spindle onto a lathe. Use the tool on the lathe to move back and forth along the spindle’s length, but do not turn on the lathe motor. Instead, rotate the spindle manually to identify the specific bending point. This step is crucial for pinpointing the exact location where the spindle needs adjustment.
(2) Once the bending point is identified, draw a circle around it. The size of the circle should be adjusted based on the spindle’s diameter—this is something that requires some trial and error. Using a small hammer, gently tap around the circumference of the circle, ensuring even strikes. The goal here is to apply enough force to slightly expand the metal at the bending point, allowing the spindle to straighten itself out.
(3) After approximately 30 minutes of tapping, return the spindle to the lathe for another check. Continue the process of tapping and checking until the desired level of straightness is achieved. From my observations, when dealing with a spindle of 100 mm diameter, it typically takes around 100 minutes of tapping to achieve noticeable results.
This method is straightforward and effective for larger spindles. However, it’s important to note that for spindles with diameters smaller than 90 mm, this approach may not yield optimal results. Smaller spindles tend to have more severe bending issues, making them harder to correct using this technique.
While this method has proven useful in many cases, it does require patience and attention to detail. Additionally, it might not be suitable for all types of materials or extreme bending scenarios. For instance, if the bending is too severe or the spindle is made from particularly hard metals, additional steps or professional tools might be necessary. Overall, this is a valuable workaround for situations where replacing or drastically altering the spindle isn’t an option.
Although the method described above has worked well for me, I encourage anyone attempting it to exercise caution and perhaps seek expert advice if unsure. The stakes are high when working with critical components like spindles, so ensuring safety and accuracy is paramount.