Solid-Lubricant-Embedded Bearing
Manufacturing on Demand
Solid-Lubricant-Embedded Bearing
JDB Solid-Lubricant-Embedded Bearing
Advantages in Standard Parts like Guide Bushes and Slides:
- We operate our own copper foundry, ensuring stable quality of raw materials and timely delivery.
- Our factory layout is clear, and the production line is well-defined, allowing for mass production.
- We are equipped with advanced Japanese and Taiwanese lathes, Taiwanese grinders, and four-axis machining centers to meet high precision and high-volume efficiency demands.
- We are also equipped with advanced Japanese inspection equipment and three-coordinate measuring machines to meet different precision inspection requirements from customers.
The Advantages of Self-lubricating Bearings: Modern designs are driving huge demand for today’s self-lubricating bearing materials. These bearings require no maintenance even under severe conditions and heavy loads. As cost pressures rise, the demand for reliable operation of equipment and plants also increases. Metallic self-lubricating bearings provide maintenance-free operation and self-lubrication over long terms, making the design of reliable long-term self-lubricating systems possible. These bearings are suitable for a wide range of applications including high-load and low-speed conditions, and in environments where traditional lubrication is inadequate or prohibited, such as in dusty, high impact, or irradiated conditions.
Custom Parts: We can source materials of different compositions, shapes, and sizes from our own copper plant according to customer requirements. We then precision machine these materials based on customer drawings, consistently meeting special needs from clients around the world on time and with high quality.
The Self-lubricating Bearing Concept: Self-lubricating bearings operate without the need for frequent lubrication. Our goal is to ensure that bearings perform optimally and have the longest possible lifespan under various conditions. The basic principle is that during the initial operation, a solid lubricant film is created through frictional transfer on the bearing surfaces. This film acts as a barrier, reducing direct contact between moving parts and thus extending the life of both the bearing and the shaft.
Material Structure: JDB materials are made from high-strength copper alloy, with holes machined into the working surface and filled with solid lubricants according to operational requirements. The high-strength copper alloy offers a high load capacity, while the solid lubricant creates a low-friction pair. The bearing surface is designed with a pre-lubrication film to quickly transfer the solid lubricant to the mating parts, effectively forming a solid lubrication film upon first contact.
Material Structure
- Solid Lubricant Film
- Solid Lubricant Plug
- Bronze Backing
Machined cast bronze bearings provide a simple and economical bearing application method. They feature high load capacity, good corrosion resistance, and flexible dimensional machining. Different grades of bronze alloys can be provided according to varying operating conditions, and can be machined into different forms as required. They offer higher dimensional accuracy compared to wrapped bronze bearings. These bearings offer technically and economically favorable solutions with high load capability, low weight, and good corrosion resistance. viiplus can offer different types of bronze alloys according to the required lifetime, service, etc. The tolerance is much tighter than that of wrapped bronze bushes.
Availability
Continuous Cast
Continuous cast bronze bushing bearings are produced through an efficient process that ensures high quality and performance. Their unique properties make them suitable for demanding applications in various industries, highlighting their importance in modern engineering solutions.
Wrought
Viiplus offers quick turnaround on a wide variety of wrought alloys, including our standard bronze bearings as well as custom alloys. We also provide flange bushings, wear plates, thrust bearing washers, and various other sizes to meet specific needs.
Applications: Continuous cast bronze bushings are widely used across various industries due to their robust properties:
Continuous cast bronze bushing bearings are produced through an efficient process that ensures high quality and performance. Their unique properties make them suitable for demanding applications in various industries, highlighting their importance in modern engineering solutions.
- Heavy Machinery: Their hardness and impact resistance make them ideal for construction and agricultural equipment.
- Hydraulic Systems: With excellent heat resistance and mechanical stability, they are often used in hydraulic cylinders and motors.
- Automotive Components: These bushings support critical moving parts in vehicles, contributing to overall performance and reliability.
- Industrial Equipment: Used in manufacturing tools and machinery, they provide durability in high-wear applications.
Continuous Cast
Continuous cast bronze bushings are essential components in various mechanical systems, known for their durability, strength, and resistance to wear. The continuous casting process allows for the efficient production of these bushings, ensuring a uniform microstructure and reducing the need for extensive machining.
JDB Solid-Lubricant-Embedded Bearing
Material Composition and Properties
| Grade | Material code | ||||||
|---|---|---|---|---|---|---|---|
| Composition | CuZn25Al5Mn4Fe3 | CuSn5Pb5Zn5 | CuAl10Ni5Fe5 | CuSn10Pb | CuSn7ZnPb | CuSn12Pb | |
| Density (g/cm³) | 8 | 8.9 | 7.8 | 8.9 | 8.8 | 8.9 | |
| Hardness (HB) | >210 | >70 | >140 | >80 | >75 | >95 | |
| Tensile Strength (N/mm²) | >750 | >200 | >600 | >330 | >270 | >260 | |
| Yield Strength (N/mm²) | >450 | >90 | >260 | >170 | >130 | >150 | |
| Elongation (%) | >12 | >15 | >10 | >6 | >16 | >8 | |
| Coefficient of Linear Expansion (/°C) | 1.9×10^-5 | 1.8×10^-5 | 1.6×10^-5 | 1.8×10^-5 | 1.8×10^-5 | 1.8×10^-5 | |
| Max. Temp. (°C) | -40~+300 | -40~+400 | -40~+400 | -40~+400 | -40~+400 | -40~+400 | |
| Max. Load (N/mm²) | 100 | 60 | 50 | 70 | 70 | 70 | |
| Max. Speed Dry (m/min) | 15 | 10 | 10 | 10 | 10 | 10 | |
| Max. PV (Lubrication) (N/mm²*min) | 200 | 60 | 60 | 80 | 60 | 80 | |
| Compression Deformation under 300N/mm² | <0.10mm | <0.05mm | <0.04mm | <0.05mm | <0.05mm | <0.05mm |
Solid Lubricants
| Solid Lubricant | Features | Typical Application |
|---|---|---|
| SL1 Graphite+add | Excellent resistance against chemical attacks and low friction. Temp limit 400°C | Suitable for general machines and under atmosphere |
| SL4 PTFE+add | Lowest friction among all options, performs well in both dry and water lubrication, Temp limit 300°C | Suitable for ship, hydraulic turbine, gas turbine etc. |
Advantages of Bronze Bearings:
Continuous Casting ProcessThe continuous casting process begins with molten bronze being poured into a specially designed carbon graphite die. This die is surrounded by a cooling jacket through which water circulates, rapidly cooling the molten bronze as it exits the die. The key steps in this process include:
- Pouring: Molten bronze is continuously fed into the mold, allowing for the creation of long shapes such as tubes or bars.
- Cooling: As the bronze exits the die, it solidifies due to the cooling jacket, which helps control the temperature and solidification rate.
- Withdrawal: The solidified bronze is pulled from the die by rollers or pinch rolls, maintaining a steady flow and ensuring consistent dimensions.
This method results in a fine grain structure due to rapid cooling, leading to a homogeneous microstructure that enhances mechanical properties. The continuous casting technique also minimizes stock allowances, reducing machining time and costs.
Advantages of Continuous Cast Bronze BushingsContinuous cast bronze bushings offer several benefits that make them suitable for various applications:
Continuous Cast
Continuous cast bronze bushing bearings are produced through an efficient process that ensures high quality and performance. Their unique properties make them suitable for demanding applications in various industries, highlighting their importance in modern engineering solutions.
Wrought
Viiplus offers quick turnaround on a wide variety of wrought alloys, including our standard bronze bearings as well as custom alloys. We also provide flange bushings, wear plates, thrust bearing washers, and various other sizes to meet specific needs.
JDB Solid-Lubricant-Embedded Bearing
Alloy Material
| Type | Material Code | ||||||
|---|---|---|---|---|---|---|---|
| Corresponding Brands | |||||||
| GB1776-87 China Brands | ZCuZn25Al6Fe3Mn3 | ZCuSn6Zn6Pb3 | ZCuAl10Fe3 | ZCuSu10P1 | ZCuSn6Zn6Pb3 | HT250 | GCr15 |
| ISO1338 International | GCuZn25Al6Fe3Mn3 | GCuSn6Zn6Pb3 | GCuAl10Fe3 | – | CuSn6Zn6Pb3Fe3Ni5 | – | B1 |
| DIN Germany | G-CuZn25Al5 | GB-CuSn5Zn5Pb5 | GB-CuAl10Ni | GB-CuSn10 | GB-CuSn6Zn6Pb3Ni | – | 100Cr6 |
| JIS Japan | HBsC4 | BC6 | AIBC3 | BC3 | BC6 | FC250 | SUJ2 |
| ASTM/UNS America | C86300 | C83600 | C95500 | C90500 | C83600 | Class40 | 52100 |
| BS England | HTB2 | LG2 | AB1 | PB4 | LG2 | – | – |
