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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 flyers to get an idea of some possible applications for ZEDEX® engineering & high-performance plastics or use the filter below to find application cases similar to those you are looking for and click on the link of each application to view the case study.

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 study it later, you can do it here.

If instead you want to download our complete application catalogue

and study it later, you can do it here.

CASE STUDIES

ENG, ZX-100K

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.

Bronze, ENG, ZX-100K

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.

ENG, sintered-bearing, ZX-530

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.

ENG, ZX-750V5T

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.

ENG, ZX-750V5T

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.

ENG, ZX-410

Components in commercial aircrafts

Material

ZX-410

Description of the application

Bushings made from ZX-410 in pumps
for drinking water supply in aircraft.

ENG, ZX-530

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.

ENG, ZX-324V11T

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.

Bronze, ENG, ZX-410

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

ENG, ZX-410

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.

ENG, ZX-100K

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.

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