Repairing a Cylinder Barrel for BIG D11 Bulldozer! | Machining, Welding & Honing
Summary
TLDRThe video follows Kurtis doing a cylinder rebarrel job on a bulldozer blade tilt cylinder. He shows the worn area of the barrel that needs replacing, cuts the original barrel off to salvage the head flange, machines a new barrel section, welds the head flange onto it, hones the new barrel to spec, welds on the other barrel end, reclaims the cylinder eye, and completes the rebuild. There is friendly banter with his partner Karen and the camera operator, demonstrating the amiable shop environment.
Takeaways
- 😀 This video covers the process of rebarreling a bulldozer blade tilt cylinder barrel that had an imperfection
- 👷♂️ The original barrel was borderline out of spec due to being oversized, so a full rebarrel was required
- 🔨 The old barrel was cut off, and a new pre-honed tube was machined to size and welded on
- 📏 The heat affected zone caused the barrel to shrink 0.4mm which needed to be honed out
- 💎 Rough honing stones were used first, followed by finishing stones to get the final dimension
- ⚙️ The barrel end was precisely reattached using alignment marks taken before disassembly
- 🌡️ Preheating was used for the large barrel weld to prevent too rapid cooling
- 🛠️ The weld tops were sanded smooth and the eye was reclaimed after honing was complete
- ✅ The rebarreling restored the cylinder to 100% standard spec
- 😊 The completed job was wrapped up, strapped down and returned to the happy customer
Q & A
What is the name of the part being worked on?
-A blade tilt barrel off a D11T bulldozer, used to tilt the blade left and right.
What was the original job for this part?
-To have an eye reclaim and the barrel rehoned, as there was an imperfection in the barrel.
Why couldn't the imperfection in the barrel be honed out?
-The barrel was already 8 thou oversized, which is borderline out of spec. More material would need to be removed, making it way out of spec.
What is the solution for the barrel imperfection?
-To do a full barrel replacement by machining and welding a new barrel.
What material is used for the new barrel?
-Pre-honed ST52 steel tube, with 10.5 inch ID and 12.75 inch OD.
What welding process is used?
-GMAW or MIG welding, using a dual shield wire backed up with Argon/CO2 shielding gas.
How much did the heat from welding shrink the barrel?
-0.4 thou in the heat affected zone, which is pretty standard.
What tools are used to bring the new barrel to the proper dimensions?
-Rough honing stones, then finishing stones to obtain the final size and surface finish.
How will the old barrel eye be refurbished?
-A standard eye reclaim procedure will be done, but not recorded, to bring it back into spec.
What is the final step once all machining and welding is complete?
-The part will be wrapped, strapped down securely, and shipped back to the customer.
Outlines
😀 Introducing the bulldozer blade tilt barrel machining job
This paragraph introduces the job of machining a bulldozer blade tilt barrel. It explains that bulldozers have left and right blade tilt cylinders to tilt the blade and carry loads. The customer wanted to reclaim the eye and rehone the barrel due to an imperfection, but it was too oversized to just hone out the imperfection. So they will need to do a full rebarrel instead.
😕 Discussing clearance issues when machining the barrel
This paragraph discusses the clearance issues when machining the odd shaped barrel using button tools. There is limited ability to extend the tools before they become less rigid. New longer button tool holders will need to be made to improve reach and rigidity for future jobs.
🚧 Cutting apart and machining new barrel pieces
This paragraph covers cutting the old barrel pieces apart from the welds. It then explains machining the new barrel material to size based on the standard dimensions. The head flange is test fitted before the barrel is welded.
⛏️ Noise interruption from railway bridge pile driving
This paragraph notes the loud noise from nearby pile driving for a new railway bridge. It is expected to continue for a couple more weeks until the bridge lift is completed.
🌡️ Welding the barrel and letting it cool before honing
This paragraph explains the weld filler and gas used to weld the barrel pieces together. After allowing it to cool, it will be honed to size. Reference is made to previous honing videos for more detail.
🐶 Staffy interruption and comedy during barrel honing
This paragraph contains comedy and interruptions from the shop dog Staffy during the barrel honing process. The rough honing is completed and it is within tolerance before starting the finish honing.
😅 Outtakes from multiple failed recording attempts
This paragraph contains outtakes from multiple failed recording attempts, with comedy and frustration from mistakes captured during the process.
🎉 Completion of the barrel reconditioning job
This closing paragraph notes the successful completion of the barrel reconditioning job. The eye reclaim still needs to be done but will not be recorded. The barrel is now within specification and ready to be returned to the customer.
Mindmap
Keywords
💡rebarrel
💡cylinder
💡honing
💡heat affected zone
💡button tool
💡bore gauge
💡gland
💡dual shield welding
💡roughing
💡cross-hatching
Highlights
The barrel has an imperfection that is hard to remove by honing
The imperfection will require rebarreling the cylinder
Cutting the barrel and head flange apart to remove the old barrel
Machining a new barrel section from pre-honed tubing
Shrink fitting the head flange onto the new barrel
Welding the head flange to the barrel
Machining the barrel to length and adding a weld prep
Honing the new barrel to size
Realigning the barrel end using alignment marks
Tack welding the barrel end in place
Welding the barrel end fully
Sanding welds smooth
Reclaiming the cylinder eye
Overview of process to rebarrel a cylinder
Job is now complete and cylinder is ready for customer
Transcripts
how you going guys Kurtis from Cutting Edge engineering today's job we have a blade tilt
barrel off a d11T bulldozer and as the name suggests this is used for exactly that is to
tilt the blade left to right because this is a newer model Dozer it does have a left and
a right blade tilt cylinder so you can actually tilt the blade all the way back in order to carry
a load or you can tilt it all the way forwards or you can tilt it left or right so originally
this job came in to have an eye reclaim and it's Barrel rehoned the customer did make
me aware that there was an imperfection in the barrel and they'd like to see if we could hone
that out so we put it up on our honing machine I did take a bore measurement and it turns out
the barrel is already about 8 thou oversized which is border line being out of spec which
means I could only really do a finish hone in order to reset the cross-hatching after
doing a quick cycle with the roughing stones that imperfection became far more pronounced
so even though I can feel that imperfection with my finger it is hard to show on camera so I have
used the nikko pen blued up that area and then I've used a honing stone to really show how bad
that imperfection is so in order to get it to clean up I would have to take out another 10 thou
of material and that would just make the barrel way out of spec oversizing a barrel is something
you could do but that does mean you do have to take it 30 thou oversize in order to buy a seal kit
from the manufacturer so you can keep using this cylinder those seal kits aren't always available
and you still need to identify the barrel within the fleet of machines the customer has as being
oversized so when they did order parts they could order the correct seal kit but that's not something this
customer wants to do they like everything to be 100% standard what that means is we're going to
be doing a rebarrel we're going to get it set up so we can remove the barrel and the head flange
clearance is clearance heh
there
we'll go 70
[Karen] the corner of the tool post is getting close nah or you got enough room
so an ongoing issue I have is clearance when I'm using the button tools because
this is very odd shaped and there are a few obstacles around there's not a
great deal I can extend that tool out before it becomes less rigid so what I
am planning on doing is making up some new button tool holders something that
will reach quite a distance so we will end up doing a shot made videos very shortly
so now we found the base of the weld joint between the barrel and the barrel end I'm
not going to go and machine that through all the way while it's set up in the lathe
because there's nothing supporting that end of the barrel I don't want
it to break loose so I am going to take it over to the welding area I'm going to cut
the rest of it with a grinder and I'll heat up the barrel and separate the two parts
so now that we've got those two pieces separated I can take the barrel back over to the lathe
set that up and remove the head flange
so now we've found the bottom of the weld joint for the head flange to the barrel
we're going to take this out and get them separated
now that we've got those two separated we can get on to machining the new piece
up for our barrel and the piece of material we're going to be using it
is pre honed st52 tube the ID is 10 1/2 inches and the OD is 12 and 3/4 inches
so the first thing I'm going to do is machine the OD down half an inch
which will bring it down to 12 and 1/4 inches to suit the standard barrel
once that's done I need to machine down one end to 300 mil to fit the head flange
now that that's done we're going to get this out of the lathe so we can fit the head flange to the barrel
[beep]
[loud banging]
if you're wondering what that noise is we're going to show you
[loud banging continues]
so what those guys are over there are doing their driving in peers for the new
Railway Bridge that's being set up out the back for the new maintenance facility so
we're going to have to hear that for the next couple of weeks and then hopefully we'll get
some footage of when they do the bridge lift right now that that head flange is shrunk down
onto that barrel and grabbed a hold of it we're going to get this set up on the rotator
so we're ready to weld the filler material we're going to be using is cig verticor in
a 1.2 that is a dual shield wire we'll be backing that up with Argoshield
heavy which is 80% argon 20% CO2 be running that at about 27 volts and 6 1/2 metres of wire a minute
so that's fully welded now that took about 10 layers of weld and about half an hour
so we're going to let that cool down then we need to set it back up in the lathe
[squawking] come on
[squawking continues]
come on
[giggles]
so before we go back to the lathe I need to
cut this mounting plate off the old barrel and fit it to the new one
now that it's set up the first thing we're going
to do is face to head flange so it's a nice machined true surface for the gland
now I'm going to chamfer the ID so when the gland gets installed it doesn't damage the seal
so with all that done now we can flip it over machine the barrel
to length and put a weld prep on it for the barrel end
righto so that's all the machining done the next thing I need to do is hone the barrel to size
so we're not going to get into too much detail about the honing process because we have done
videos about it before so if you'd like to check them out you can go back and have a look
so we got the barrel set up I've got my stroke length set but before we
start honing we thought we'd show you how much this barrel
has actually shrunk in the heat affected zone where we've welded it
so I've set the bore gauge to zero on the far end of the barrel that hasn't been welded
and as you can see the heat affected zone has shrunk point 4 of a mil that's pretty standard
for a barrel like this with that much weld on it so because that's the tightest area of the
barrel we will have to work the honing head in that area in order to open it up to run
parallel with the rest of the barrel so we're going to start with our 45 stones
they are roughing stone and they will get through that heat effect design very quickly
so because this material is pre honed I really only have about half a mil to
come out of the ID if it was unhoned material we would have about 1 to 1.2 mil to be honed out
[staffy grunts] [squeaking]
oi where's your corn
[Karen] what are you doing you crazy dog
go
[squeak]
stay
get it
[happy squeaks]
good boy [Karen] come on
[Karen] come on on your bed
so we've completed the roughing of the barrel and it is measuring to within 0.02 of a mil
of its finished diameter so what we're going to do now is change out from
our roughing stones to our 87s which are our finishing stones we're going to run
those stones for a cycle to give us the final dimension and the surface finish we need
so that's our finishing cycle completed we need to take a final measurement
so that's reading to within less than 0.01 of a mil
tolerance is plus or minus 0.05 of a mil so we are well within spec
so now that the honing is completed I'm going to give the barrel a clean and then we
can get it set back up in the lathe so we can reattach the other end of the barrel
so this is where I made it really easy for myself by using alignment marks and taking measurements
before I machined apart the barrel because now I can use those references to get everything
back in alignment and all my measurements correct now that we've got our barrel end in
position I can tack that in place then take it out of the lathe and go and weld it up
so to weld this we're going to be using the same wire and gas combination as
we used for the head flange and I am going to give this a preheat
because I don't want the well to cool too rapidly because of the size of the part
so that joint's fully welded it took about 14 runs of weld at about 5 minutes per rotation
now I'm going to use an 80 grit sanding disc just to take the tops off the welds and remove any weld spatter
righto guys that's our rebarrel job completed I still need to reclaim the eye
but we're not going to video that we have enough videos of where we've done eye reclaims before this
is actually not in that bad a condition the eye is just slightly out of spec we're just going to
bring it back into spec for our customer so the bearings last when this is back in operation so
that's this job 100% complete we've got the eye claimed and the rebarrel done we're going to
get this wrapped up and strapped down and back to our customer thanks for watching
so we're ready to weld and what we're using is Argo ohhh [Karen] that was great
so after doing a quick roughing cycle with our roughing ughhh
so after doing a quick cycle with ohhh [ __ ] me
so after doing a quick cycle [ __ ] me I nearly said psychical
and that would take the barrel fu hmmm [ __ ]
so over sewing it oh over sighging
so we're wor uhmmm [giggle]
and this plate has a hydraulics pot uhhh [ __ ] so we're
so we're not going to ughh so we're not going to uhhhhh
woah where do we go from there [Karen] now the honing is completed
got it right so now that the honings completed I'm going to oh [ __ ]
ughhh [ __ ] words
[Karne] I've literally listened to 3 minutes of blabbering [Laughter]
[crazy laughter continues]
so ohhh [Karen] oh woah HEH [Laughter] [ __ ]
righto guys so the filler [Karen] just not righto guys
righto guys now that we've oh [ __ ] me
what was after that
righto guys so that's our rebail job completed [Karen] you want to try that word again what
[Karen] rebarrel what did I say [Karen] I don't know
[ __ ] off train
[Karen] such a nice color though it's like anodized
god they're [ __ ] hot sad and the hotter it gets the more it does
[slow metal squealing sound]
[Karen] this thing sounds sad and the hotter it gets the more it does that
hot [Karen[ hot very hot we need a thermometer where's it I got you a water bottle
[Karen] what is it like 100% humidity 35° plus a 87% humidity yuck pretty hot
[Laughter] it is bloody hot
[Karen] is that my tea towel
[Karen sighing] where the [ __ ] my 32 mil spanner gone
[Karen] is that it
[chirping]
[Karen] hello
[Karen] oh no he's taken his jacket off again
cause of your fat neck
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