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Bearing surfaces on a 7.4 tonne rotor have been precision machined by BEP in preparation for final turning operations by Boro Foundry, who manufactured the shaft for Converteam.

Designed for use in a gas-turbine power plant, the rotor is 5.6m long and has an outside diameter of 475mm.

To facilitate the installation of vibration-monitoring equipment, BEP ground all the bearing diameters and thrust faces to 0.005mm total indicated run-out (TIR), and ground the outside diameter to a surface finish of less than 16CLA.

Boro Foundry produced the rotor from a pre-machined forging supplied by Converteam.

Machining operations included turning, milling, thread milling, milling keyways, drilling and boring to produce the finished shaft ready for the fixing of the pole shoes and windings, which were also subsequently machined.

Turning operations were carried out on an 8m-long Tuscan LL950 CNC lathe.

Following grinding work by BEP, vibrator probe tracks with a surface finish of more than 0.063um Ra, 0.025mm deep x 30mm wide were diamond burnished into the shaft at Boro Foundry’s Stourbridge, West Midlands, factory.

The probes read the highly polished surface of the shaft and take a reference that checks any movement that might affect electrical and mechanical characteristics.

BEP Surface Technologies

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