SUCCESSFUL COMPONENTS AND APPLICATIONS since 1968.
Since the usage of plastic wear parts as machine element could lead to problems, the decision concerning whether, where and how, which plastic can be used, requires a high degree of experience.
For example in an existing gearbox construction, it is not enough to replace the used metal gear by a plastic one, without letting a specialist analyse the installation, construction, loads and any external influencing factors to which the gear is subjected to. In fact, to achive an optimal application, the customer should study the application as a whole.
In alternative you can choose material-selection-level-6 too! Have a look to our material selection section and let us analyse your application.
We understand the properties of plastics as intrinsic properties of the system. Through our experience we know how technical components work (such as gears, gaskets, bushings, mother screws, and other parts of general wear) and what reactions and processes inside the plastic take place during the usage and which modifications are necessary for reduce negative reactions.
Over the years, we have had the honor of being able to create added value in many sectors with our ZEDEX® plastic materials, such as performance, efficiency and durability.
We have successfully introduced ZEDEX® high-performance plastics in areas considered visionary, which allows us to talk only about some of the many applications carried out.
Take a look at our sector specific industries flyers to get an idea of some possible applications for ZEDEX® engineering & high-performance plastics or use the filter below to find case studies similar to those you are looking for.
If in these applications by way of example, you do not find data that can be translated into your application or would like more detailed information, do not hesitate to send us a request.
If instead you want to download our complete application catalogue and read it later, you can do it here below.
Download our complete application catalogue
SECTOR SPECIFIC EXAMPLES
CASE STUDIES
Sector
Axial spherical plain bearings in an electric monorail system
material
ZX-100K
Description of the application
The bearings are used in a suspension system for continuous assembly. The axial spherical plain bearings enable lateral swinging out when cornering and compensate for misalignment from production.
burden
There are high static and dynamic forces (approx. 60 kN). In addition, smaller movements of the sling take place constantly, as well as shocks during loading and unloading.
Problem
A material is required that allows maintenance-free operation due to dry running and setting options in all axes.
Troubleshooting
Special axial spherical plain bearings (outer diameter 260 mm, inner diameter 80 mm) made of steel with a sliding body made of ZX-100K are used in this application.
lifespan
No lifetime limit is expected.
advantages
Simple construction and maintenance-free operation.
Ball joint bearings for systems in rolling mills
Material
ZX-100K as a replacement for bronze
Description of the application
The spherical plain bearing is used in systems in the steel industry and is exposed to high loads and high temperatures. The bearing is available in various diameters from 140mm to 180mm. The component is provided with a threaded hole in the center for fastening.
Problem
The previous material had to be lubricated with oil, which led to enormous costs.
Troubleshooting
By switching to ZX-100K, lubrication can now be dispensed with. The warehouse is now water-cooled.
Advantages
The elimination of oil lubrication resulted in a cost advantage of over € 35,000 a year.
Bearing in franking and paper-folding machine
Material
ZX-530 as replacement for sintered bearing.
Description of the application
The bearing in franking and paper-folding machines was previously a sintered bearing. They were used to support the conveying shafts and track rollers.
Load
The bearing will be loaded by the pressure force of the track rollers.
Problem
The sintered bearings must be calibrated when mounted. The previously used sintered bushings require a complex assembly, since they need a very smooth-running with minimal clearance, which requires an accurate calibration. This also leads to high costs.
Problem-solving
Now close-tolerance injected moulded bushings made of ZX-530 have replaced sintered bushings. The inner diameter is 8 G7. The shaft has got a diameter of 8 h8. The maximum clearance is 0,049 mm.
Working life
The bearing made of ZX-530 have been successfully used as standard feature since
1997.
Advantages
Maintenance-free by dry running conditions. The bearing made of ZX-530 must no longer be calibrated when mounted. By replacing the sintered bearing, a cost reduction for both the mechanical parts and the assembly is achieved.
Bearing segments in deep-sea hammer
Material
ZX-750V5T
Description of the application
This segmental bearing, made of ZX-750V5T (Ø 700 mm), guides and leads into water the fl oating weight of 28 tons in a deep-sea hammer. This extreme stress subjected part operates in unlubricated conditions, with a 50 Hz impact frequency and a drop height of 1 m. The bearing segmented of ZX-750V5T holds the extreme conditions and runs maintenance free.
Bushing in artificial knee joints
Material
ZX-750V5T
Description of the application
The application involves bearing bushes in artificial knee joints.
Problem
High surface pressures and high wear resistance are required in order to do not exceed a max. clearance of 0,05 mm.
Problem-solving
Bearings made of ZX-750V5T (with less load ZX-100K is used) meet the extreme requirements of artificial knee joints.
Advantages
High wear resistance, high allowable surface pressure.
Bushing in loading lift
Material
ZX-100K
Description of the application
The slide bearing bushes made of ZX-100K in joints of a scissors lift for the load of storage shelving. The lift support up to 4 tons. Here bronze was replaced by the plastic material ZX-100K. The application works now maintenance-free.
Cutters in a shredding machine
Material
ZX-100K
Description of the application
The cutters are fi xed onto the shaft with rubber laces. The shredded material is leaded from a side to the other one through the shredder shafts (depending on version, one up to four shafts). On the shaft’s side there are the cutters that provide to protect the bearing from very small particles. Once a minute the cutters go up and down the wavelength for 1.500 mm.
Problem
Due to the shredded material, the cutters are expose to abrasive wear and they should not have any gap to the shaft. Also screws, staples and nails should not damage the cutters. The sealing of the bearings against dirt ingress must be permanently guaranteed.
Problem-solving
An axially fi xed split bushing made of ZX-100K is used.
Advantages
The wipers do not need to be adjusted.
Cylinder guide in mobile compactor
Material
ZX-100K
Description of the application
In the rubbish tracks mobile compactors, their hydraulic cylinders must be driven in a way to do not let them buckle. For this purpose, a suitable material is searched.
Load
The loading on the part is dependent from the ever-changing operating conditions (loading condition, rubbish mass, temperature) and may not be precisely measured.
Problem
The hydraulic cylinder should not buckle in the extended position. The enormous lateral forces and signifi cant edge compression must be supported. Accurate force measurements were not performed. The vehicle works outdoor and therefore operates in a wide temperature range,
from -20°C to +60°C. Furthermore during the working life it is always is contact with considerable pollution. The cylinder guide must be maintenance-free in dry running conditions.
Problem-solving
A machined U-profi le made of ZX-100K is used. It guides the hydraulic cylinder of the mobile rubbish compactor.
Advantages
The hydraulic cylinder is securely supported also in fully extended position and the wear of the support U-profi le is now very low. ZX-100K enables the maintenance-free operations.
Guide bushing
Material
ZX-530CD3
Description of the application
The bushing is used as guiding of a vibration generating piston in pneumatic cylinders of grinders.This produces a cross- grinding on the work-pieces.The piston is driven by compressed air (oil and water free). The cylinder is fi tted with radial slots, so that the air can enter and exit through them. The system works, in principle, as a twostroke engine. The piston stroke is 36mm at a sliding speed of 350 m/min.
Problem
So far, a coated steel sleeve which was glued into a cylindrical aluminium body, was used. Unfortunately the adhesive was dangerous to human health, the applying of the coating was laborious and had poor adhesion to the steel sleeve. The coating was also highly sensitive to shocks. Therefore, they were seeking for an easy solution in which even dry running would have been possible. A service life from 5 up to 10 years was required.
Problem-solving
Instead of a glued and coated sleeve, now a bushing of ZX.530CD3 is used, which will be polished in the inner diameter after its tight fi t in order to improve its tribologiacal properties.
Advantages
Easy installation, thanks of the cooling system by the driving air, a very low guidance clearance of 0,019 – 0,023 mm is possible, hardly measurable wear.
Guide bushing for drive element
Material
ZX-324V11T
Description of the application
The bushing supports driving elements. An accuracy of the inner diameter of the bushing of 0,0015 mm is too big. The drive should work smoothly. Two hollow shafts are coaxial assembled and the inner one is axially guided from the bushing.
Problem
The bushings should not any longer be worn out, as with the previously used bronze bushings.
Problem-solving
Thanks to very precise tolerance of bushing obtained during manufacturing, it does not need any longer to be re-machined when assembled.
Advantages
The used bushing work in dry running conditions.
Guide bushing in pneumatic cylinder
Material
ZX-530CD3
Description of the application
The bushing is used as guiding of a vibration generating piston in pneumatic cylinders of grinders.This produces a cross-grinding on the work-pieces.The piston is driven by compressed air (oil and water free). The cylinder is fi tted with radial slots, so that the air can enter and exit through them. The system works, in principle, as a twostroke engine. The piston stroke is 36mm at a sliding speed of 350 m/min.
Problem
So far, a coated steel sleeve which was glued into a cylindrical aluminium body, was used. Unfortunately the adhesive was dangerous to human health, the applying of the coating was laborious and had poor adhesion to the steel sleeve. The coating was also highly sensitive to
shocks. Therefore, they were seeking for an easy solution in which even dry running would have been possible. A service life from 5 up to 10 years was required.
Problem-solving
Instead of a glued and coated sleeve, now a bushing of ZX.530CD3 is used, which will be polished in the inner diameter after its tight fi t in order to improve its tribologiacal properties.
Advantages
Easy installation, thanks of the cooling system by the driving air, a very low guidance clearance of 0,019 – 0,023 mm is possible, hardly measurable wear.
Honeycomb structure bushing in a filament winding machine
ZX-100K as replacement for bronze.
Description of the application
The here described bearing is used in filament winding machines for the paper industry. It supports the centre sleeve, that transports the to be wrapped paper roll. The paper rolls have a diameter of 2 m and the shaft has a length of 3 m. The bearing was up-to-now made of bronze.
Problem
With the lubricated bronze bearing the precision was a problem also with a solid lubricant. A material that allows a higher precision was needed. Furthermore, a low break loose torque is required.
Problem-solving
Here a plain bearing bush made of ZX-100K with a honeycomb structure, needed to reduce
the static and kinetic friction, has been used. The bushing is manufacture with a tolerance of 2-3 hundredths of a millimetre, with an outer diameter of 185 mm, an inner diameter of 165 mm and a length of 80 mm. The groove depth is 1 mm, the groove width 3 mm. The bearing clearance is 0,05 mm.
Working life
The bushings is been successfully used since 1992.
Advantages
70% price reduction , improved precision, dry running, no high break loose torque
Industrial machine and plant production
Material
ZX-410 as a replacement for bronze
Description of the application
The spindle nuts (TR 100 x16) are used in lifting devices for the repair of railway wagons. A device consisting of each 4 individual lifters.
Load
The lifting device has got a carrying capacity of: – fi rst equipment -> 120 tons – second equipment -> 160 tons Both of them consist of 4 railways jacks each.
Problem
In many wagons repair factories railway jacks with motion nut of bronze are used. With this solution a periodical lubrication of the assembly is necessary.
Problem-solving
With ZX-410 a lubrication is only required just ones during the installation, further maintenance of the equipment is not needed.
Working life
The usage of ZX-410 motion nuts enabled an increase in service life of a minimum of three times. In order to achieve a maxi-mum working life of the motion nuts of ZX-410, they needed to be adapted to the spindle.
Advantages
less maintenanceincreasing of the working life, reduction machining time, improve of the working life of the lathe chisel, reduction of the frictional forceReduction of operating temperature, reduction of noises during motion, costs dropped signifi cantly
Orthopedic toe alignment splint
Material
ZX-324FDW2
Description of the application
This application relates to an orthopedic toe alignment splint for the post-operative usage.
Load
The splint must be loaded with at least 25 N, with a maximum thickness of only 3 mm.
Problem
A sterilisable material, that withstands the high loads and allows a stick-slip free rotation of ± 70 ° was searched. The bearing must be backlash free.
Problem-solving
Now as material ZX-324FDW2 is used. The material is dyed in RAL 7035 and satisfi es the required properties.
Advantages
Sterilisable material, high strength, high elasticity, lower friction. The material is physiologically safe.
Plain bearing bush in a press
Material
ZX-100K as replacement for bronze.
Description of the application
The bronze bushings in a press have been replaced by bushing made of ZX-100K..
Advantages
Higher damping than with bronze. Now it can work without lubrication; at the same time the wear was signifi cantly reduced.
Plain bearing bush in the hydraulic cylinder of a folding top
material
ZX-100K as a new design.
Description of the application
We were looking for a suitable material for a sliding bushing, which is used in a convertible top for convertibles. The plain bearing bush guides the piston rod of the hydraulic cylinder, which opens and closes the folding top.
Problem
There are low radial forces. However, the material has to withstand sustained temperatures up to 80 ° C and short-term temperatures up to 130 ° C, superimposed by shocks and vibrations. High shock resistance and shock absorption as well as low friction and very high wear resistance are therefore required.
Troubleshooting
In this application, plain bearing bushes made from ZX-100K with an inner diameter of 6.2 mm and a length of 8.4 mm are used.
lifespan
The plain bearing bushes have been installed as standard since 1990. Since then, no problems in use have occurred.
advantages
ZX-100K is very suitable due to its high wear and shock resistance and good shock absorption.
Plain bearing bushes for hydraulic truck tail-lift
Material
ZX-324V2T
Description of the application
The bushing showed here is built in several places in the articulated arms of the truck tail-lift.
Load
The maximum surface pressure of the plain bearing bush is 120 N/mm², the speed is 4 rpm in combination with the ingress of dirt, water and road salt in the bearing area.
Problem
Since it is a welded structure, in the bearings geometry results errors, which carry to extremely high edge pressures. Maintenance-free, dry running conditions, and quietoperations were also required. A tested composite of epoxy resin and PTFE proved to be as unsuitable (Fracture).
Problem-solving
In the articulated arms of the truck tail-lift cylindrical bushings made of ZX-324V2T, having an inner diameter of 30 mm, an outer diameter of 36 mm and a length of 30 mm are now installed.
Working life
25.000 load cycles as required. Afterwards 25.000 load cycles in the test stand, the bushing was still fully functional. Since 1996 it has been used as standard feature.
Advantages
The application works maintenance-free, there is no need for the greasy lubrication. The material supports high surface pressures.
Plain bearing bushes in truck tail lifts
material
ZX-324V2T instead of bronze.
Description of the application
The socket used here is installed at several points in the articulated arms of truck tail lifts.
burden
The maximum surface pressure of the plain bearing bushes is 120 N / mm 2, the speed is 4 min -1 in connection with penetrating dirt, water and road salt into the bearing point.
Problem
Complete maintenance-free operation (dry running) and low-noise operation are required. As this is a welded construction, geometry errors occur in the bearings, which cause extremely high edge pressures. A tested composite material made of epoxy resin and PTFE turned out to be unsuitable (breakage).
Troubleshooting
Cylindrical slide bearings made of ZX-324V2T with an inner diameter of 30 mm, an outer diameter of 36 mm and a length of 30 mm were installed in the articulated arms of the tail lift.
lifespan
25,000 load changes were required. After 25,000 load changes on the test bench, the plain bearing was still fully functional. The standard installation has been carried out since 1996.
advantages
The application works maintenance-free and there is no need for grease lubrication. The material can withstand high surface pressures.
Plunger guide in car-body press
Material
ZX-100K
Description of the application
The application relates to slideways as plunger guide in a car-body press. This one was converted and tested in the “New materials for guides in highly-stressed forming machines” research report. Several different materials, including ZX-100K, were tested.
Load
The press pressing force is 8.000 kN. The stroke rate is 18 strokes per minute. The ram stroke is 705 mm. The maximum short-term surface pressures are approx. 120 N/mm². The maximum sliding speed is 25 m/min.
Problem
It should work without any lubrication in order to allow a maintenance-free guide and to do not soil the pressed products with lubricant. The guide clearance should be as small as possible. The guide should be designed with a negative clearances (with preload).
Problem-solving
ZX-100K turned out as suitable material for the slideway. These slideways were monitored in a fi eld trial over 1 year using measurement technology.
Working life
After a year production of 530.000 pieces in dry running conditions, only a very slight increase in the clearance, of approximately 0,015 mm, resulted. Other tested materials such e.g. ceramics, coating materials (DLC: diamond-like carbon, WC: tungsten carbide) were not suitable for this application. Working life over 20 years with 24 hours of continuous operation.
Advantages
Maintenance-free, no soiled products.
Plunger guide in car-body press
Material
ZX-100K
Description of the application
The Vairo Shuttle is used for the pre-treatment of the coachwork. It transports and pivots the car body during the pre-treatment in purifi cation
tanks, in which sometimes some aggressive chemicals are used. The bushings and washers are assembled as standard features in the arrow marked positions.
Problem
High edge pressure. The material must have a good chemical resistance.
Problem-solving
ZX-100K is used as material, since it has got the required properties
Working life
Three years working life, despite the usage of a soft, 16 μm Rz rough shaft.
Advantages
Dry running, Maintenance-free.
Railway jacks motion nut
Material
ZX-410 as a replacement for bronze
Description of the application
The spindle nuts (TR 100 x16) are used in lifting devices for the repair of railway wagons. A device consisting of each 4 individual lifters.
Load
The lifting device has got a carrying capacity of: – fi rst equipment -> 120 tons – second equipment -> 160 tons Both of them consist of 4 railways jacks each.
Problem
In many wagons repair factories railway jacks with motion nut of bronze are used. With this solution a periodical lubrication of the assembly is necessary.
Problem-solving
With ZX-410 a lubrication is only required just ones during the installation, further maintenance of the equipment is not needed.
Working life
The usage of ZX-410 motion nuts enabled an increase in service life of a minimum of three times. In order to achieve a maxi-mum working life of the motion nuts of ZX-410, they needed to be adapted to the spindle.
Advantages
less maintenanceincreasing of the working life, reduction machining time, improve of the working life of the lathe chisel, reduction of the frictional forceReduction of operating temperature, reduction of noises during motion, costs dropped signifi cantly
Rolls in adhesive roller machine
Material
ZX-100K as replacement for polyamide
Description of the application
In this application it is about rolls in a adhesive roller machine. Previously as material polyamide was used.
Problem
In this application a high precision, dimensional stable and anti-adhesive material is required. The accuracy and precision of the clearance, which is extremely important for the functionality of the machine, had to be improved. Polyamide should be replace because of its dimensional changes due to the high moisture absorption.
Problem-solving
Polyamide’s rolls were replaced from the ones made of ZX-100K.
Advantages
Higher precision, thereby precisely defi ned clearance (0,3 mm before, 0,03 mm now), anti-adhesive properties, better machinability and thereby cheaper, better surface quality. Higher wear resistance. The surface can be easily re-machined if necessary.
Round guide system in sintered metal press
Material
ZX-530 as replacement for bronze.
Description of the application
The following described plain bearing bushes are used in tool adapters for sintered tools in hydraulic presses, cross head and base plates. The up-to-now used bronze bushings in the column guide, had to be lubricated.
Load
Centrifugal forces up to 200 N/mm², speeds up to 6 m/min.
Problem
The fine dust is attracted from the greasy, making the device rapidly soiled. In the future
during the tools’ changing, the adapter should not be washed completely. So far, high environmental impact (disposal of used greasy enriched with metal powder, etc.)
Problem-solving
Thanks to a preload bushings made of ZX-530, with an optimized honeycomb structure on the inner diameter, the penetration of aggressive fi ne dusts on the sliding surfaces is prevented.
Working life
With this system so far 500.000 parts were manufactured, which is equivalent to 1 million hubs.
Advantages
Time saving through the elimination of the lubrication process and during tool changing, additional savings of lubricant and of disposal costs. Thanks to the dry running conditions the guides and tools stay clean.
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