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ZKL Research and Development

ZKL, a.s.Jednovnická 8, BrnoCzech RepublicTelephone: +420 544 135 120E-mail: head@zkl.cz

WWW.ZKL.EU

ZKL Výzkum a vývoj, a.s.Jedovnická 8, BrnoCzech RepublicTel.: +420 544 135 171E-mail: zkl@zkl.cz

Testing Laboratory

• Basic dynamic load tests • Limiting speed tests • Metallographictests • Characteristics – Chemical composition – Maximumpermissible levelsof otherelements O2 ,Ti,

Al, etc.for steel • Mechanical Properties • Hardnesstest • Micro-purityofmaterial • Microstructureofmaterial• FEM results verification • Production of prototypes

Measuring and control

• ZKL-ResearchandDevelopment,Inc.hasthenecessaryequipmentforallmeasurableparameters. • MeasurementLab: • Roundness • Contour • Optical3DMeasurement • Length measuring systems

Diagnostics

Most common types of bearing damage which can lead to shortened life of bearings or applications are often caused by: • Impropermaintenanceprocedures• Improperinstallationandsetup• Inadequatelubrication

Don’tsolveimmediateproblemonlybysimpleinstallationofthenewbearings–solvecauseofbearingfailure.ZKL is able to extend bearing life, increase productivity and reduce maintenance costs by identifying and resolving issues around the selection of bear¬ings, mounting, lubrication and applications.

Dynamic Analyses:• ModalAnalysis(NaturalFrequencies)• FrequencyResponseonHarmonicExcitation

Optimization Analyses:• Parametric Optimization• Topological Optimization• Calibration of Material Models

Analyses in the Field of Bearings• Stress and strain analysis• Evaluation of the structure stiffness• Determinationofthereactionmomentinbearing• Optimization of the ring raceways geometry• Determinationofthelimitmisalignment

Optimization of inner design of NEW FORCE bearing 22211– dynamic load rating higher by more than 30 %

Global vs. local model

Determination of the limit misalignmentof theball bearing:

  mesh of global model 10 772 elements   mesh of local model 114 854 elements

Department of Technical support sales

Application engineering – Calculations• Stressanalysis(analytical)customerApplications–MathCad• AnalysisofbearinglifeaccordingtoISO281aISOTS16281–MathCadaKISSsoft• Creationofgenericmodelsforquickcreationofmodelsanddrawings(biddingprocessimprovement)–Creo,MathCad• Comprehensiveanalysisofthestrengthanddurabilityofgearboxes–KISSsoft:

Application engineering – Assembly• Developingofassemblymethods–Creationandmanagementofcomprehensivefittinginstructions• Creating ofassemblymanuals onyour applications• Managementofassembly processesat the customer• Creating of specialbearingassemblymanuals

Application engineering – Training• Create and managetraining materialsaimed at: –Basicknowledgeofthebearingissues – Special bearings – Applicationbearingcalculations – Bearings applications

Services Offered:• Analysisofproblems-findtheproblemincollaborationwithDepartmentofTechnicalAnalyses• Proposesolutions–incollaborationwithConstructionDepartment• Customer support in bearing selection and calculations • Support for selection of lubrication and fits • Application of specific mounting instructions • Costumer support on the spot • Provides related training and presentations • Recommendslubricationconditionsandtypeoflubrications• Training

Prototype Workshop

•ZKL–ResearchandDevelopment,Inc.ownaprototypeworkshopinwhichitispossibletoproducedifferentkindofprototypes.

•Theprototypeworkshopisequipped: • CNC lathe • CNC lathe for hard turning • Grinder • Wire cutting • Press • Additionalequipment

Construction Department

1. Basic bearing design2.Detaileddimensionalbearingscalculation3. Strength calculation of bearings4. Tender bearings documentation5.ConstructionDrawingsofbearings6.ConstructionDrawingsofspecialtoolsandtestconditions

Developmentofconceptisfinishedcreatingtheconceptualdesign(model):

ConstructionDrawingsofspecialtoolsandtestconditions:

Department of Technical Analyses

1. Optimize inner design of new bearings • higherparametersof“NEWFORCE“bearings2.Solvewiderangeof“non-bearing“problemswithinZKLGroup • gripping jaws, pipe bending, etc.3. Offer service in the field of Finite Element Analyses to external customers • cooperationwithResearchCenterofManufacturingTechnology

Finite Element Analysis The Finite element analysis allows you to de-tect critical places in structure of industrial products in following:• productive machines• transportation• aviation• energetic industry• design of gearboxes and othermechani-calparts

software equipment:• MSC. Patran&MSC. Marc• CreoSimulate(formerlyPro/MECHANICA)

Offered Finite Element AnalysesStructural Analyses:• with linear material model• withnon-linearmaterialmodel• geometrically linear• geometricallynon-linear• contact problems• with combined loading