This 850 HP rotor used for a chemical compressor was failing due to a bearing fit damage to the shaft. Western Machine Works inspected the part and determined that the damage was not repairable. A new shaft was reverse engineered, manufactured complete, and installed within the customer’s production schedule. 

Project:

• Part: 850 HP Rotor
• Details: 53″ overall length
• Customer: Electric motor distributor

Challenge:

• Bearing fit damage to shaft was not repairable.
• Bore out existing shaft and manufacture new shaft from 4142 HRHT material.
• Concentricity of shaft and rotor critical.
• Fast turnaround required.

Engineered Solutions:

• Manufacture and install carrier rings for boring out the shaft.
• Bore out the existing shaft and skim cut the rotor bore within .001″ to OD of rotor.
• Reverse engineer the shaft and create CAD drawings of the rotor assembly.
• Manufacture the new shaft complete prior to installation.
• Install the new shaft in the rotor with .003″ interference fit.

Result:

• The new shaft was installed in the rotor complete saving time and cost.
• Concentricity tolerances were achieved.
• The machined rotor and new shaft were completed within the customer’s production schedule.

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