Beware of expedited spindle repairs
Published by: Cutting Tool Engineering
Written by: Bob Hodge
Every manufacturer looks for ways to add value for customers and derive value from suppliers. With machine tool spindle repair, end users can gain value by receiving a complete, comprehensive repair that is done quickly and economically.
Spindles are the heart and soul of machine tools and the most precise, heavily stressed components of a machine. Special care, therefore, must be taken to ensure that spindles are designed and built to provide the required accuracy and longevity. When a spindle degrades, a machine tool either does not hold specified tolerances or does not produce parts at all. In any case, it costs money.
When a spindle goes down, it is natural to want a machine back up and running as soon as possible. Having a spindle down in the middle of a job with a tight delivery is not a good feeling. However, although you need a spindle repaired quickly, it must be repaired correctly. A fast but substandard repair is not much consolation if part tolerances do not hold or a spindle quickly fails again.
Trust, but Verify
So how do you know that a spindle will be repaired as quickly as possible without cutting corners or taking shortcuts regarding the quality and completeness of a repair? The answer is transparency. A spindle repair company should provide proper documentation so customers know they are deriving value from spindle repairs.
In most machine tool spindles, there are 250 to 300 individual components and assembly characteristics that impact performance and longevity. For a comprehensive repair, each of these must be checked and evaluated for suitability. Since many tolerance measurements are in microns, components should be absolutely clean and at the proper temperature to accurately inspect them. To accomplish this, a 24-hour turnaround for a proper spindle rebuild is hardly sufficient. It can take that long for individual components to reach the proper temperature for inspection. A basic expedited repair should take three days from receipt of a spindle to shipping it back to a customer.
All these significant characteristics should be documented clearly by a spindle repair company for a customer to see. Photos of spindle components that show conditions and damaged areas are important for the knowledge and understanding of a customer. The cause of spindle failure, including analysis, should be noted so spindle performance or longevity can be assessed for potential improvement. It is often possible to make changes to bearings or sealing systems to enhance spindle performance or durability.
Test and Measurement
After a spindle is reassembled, test bar runouts should be measured and documented. Drawbar pull forces should be set and documented, and any sensors or encoders used should be tested.
The final assembly performance characteristics should be documented during a complete runoff. Documentation should include the spindle’s steady-state operating temperatures, details of the bearings used in the repair, and running vibration and balance characteristics. The vibration spectra at each end of the spindle also provide valuable information, which can be used as the baseline for a predictive maintenance program.
If all this sounds like a lot, that is because it is. Proper documentation usually requires about 20 pages. However, that gives enough information so a customer can understand what a suitable spindle assessment and rebuild look like — specifically, what was wrong with a spindle and what was done to repair it. This level of transparency allows a customer to know that a comprehensive repair was performed and the cost was justified.
If you are accustomed to receiving a single page with an invoice for a spindle repair, evaluate whether you are getting the kind of value you expect and deserve from your spindle repair partner.
To read the article in Cutting Tool Engineering – visit here
Spindle Repair Locations in the Midwest and Southeast
Spindle RepairsTwo spindle repair locations to better serve our customers.
At Advanced Spindle Technology, we understand the importance of repairing spindles in a timely manner. That’s why we have established spindle repair facilities in two major manufacturing areas. Our Midwest service facility is located in Cuyahoga Falls, Ohio, and our Southeast service facility is in Winston-Salem, North Carolina.
Being close to our customers allows us to quickly and efficiently provide spindle repair services to get our customers back up and running FAST. For a no-obligation quote, click here.
If you would like to see all our videos, visit our YouTube channel.
Article: Beware of expedited spindle repair
Informative, NewsBeware of expedited spindle repairs
Published by: Cutting Tool Engineering
Written by: Bob Hodge
Every manufacturer looks for ways to add value for customers and derive value from suppliers. With machine tool spindle repair, end users can gain value by receiving a complete, comprehensive repair that is done quickly and economically.
Spindles are the heart and soul of machine tools and the most precise, heavily stressed components of a machine. Special care, therefore, must be taken to ensure that spindles are designed and built to provide the required accuracy and longevity. When a spindle degrades, a machine tool either does not hold specified tolerances or does not produce parts at all. In any case, it costs money.
Trust, but Verify
So how do you know that a spindle will be repaired as quickly as possible without cutting corners or taking shortcuts regarding the quality and completeness of a repair? The answer is transparency. A spindle repair company should provide proper documentation so customers know they are deriving value from spindle repairs.
In most machine tool spindles, there are 250 to 300 individual components and assembly characteristics that impact performance and longevity. For a comprehensive repair, each of these must be checked and evaluated for suitability. Since many tolerance measurements are in microns, components should be absolutely clean and at the proper temperature to accurately inspect them. To accomplish this, a 24-hour turnaround for a proper spindle rebuild is hardly sufficient. It can take that long for individual components to reach the proper temperature for inspection. A basic expedited repair should take three days from receipt of a spindle to shipping it back to a customer.
All these significant characteristics should be documented clearly by a spindle repair company for a customer to see. Photos of spindle components that show conditions and damaged areas are important for the knowledge and understanding of a customer. The cause of spindle failure, including analysis, should be noted so spindle performance or longevity can be assessed for potential improvement. It is often possible to make changes to bearings or sealing systems to enhance spindle performance or durability.
Test and Measurement
After a spindle is reassembled, test bar runouts should be measured and documented. Drawbar pull forces should be set and documented, and any sensors or encoders used should be tested.
The final assembly performance characteristics should be documented during a complete runoff. Documentation should include the spindle’s steady-state operating temperatures, details of the bearings used in the repair, and running vibration and balance characteristics. The vibration spectra at each end of the spindle also provide valuable information, which can be used as the baseline for a predictive maintenance program.
If all this sounds like a lot, that is because it is. Proper documentation usually requires about 20 pages. However, that gives enough information so a customer can understand what a suitable spindle assessment and rebuild look like — specifically, what was wrong with a spindle and what was done to repair it. This level of transparency allows a customer to know that a comprehensive repair was performed and the cost was justified.
If you are accustomed to receiving a single page with an invoice for a spindle repair, evaluate whether you are getting the kind of value you expect and deserve from your spindle repair partner.
To read the article in Cutting Tool Engineering – visit here
Transparency in our spindle reporting
Informative, Spindle RepairsAt Advanced Spindle Technology, we are committed to providing a detailed report documenting the complete spindle repair process. In most machine tool spindles, there are from 250 to 300 individual components and assembly characteristics that impact performance and longevity. For a comprehensive repair, each of these must be checked and evaluated for suitability.
In this video, Bob Hodge, President of Advanced Spindle Technology, talks about the importance of our reporting.
If you’re interested in learning more about our reporting process, contact us.
120,000 RPM Spindle – Check out the video
UncategorizedA better-balanced spindle runs smoother, quieter, cooler, and longer.
It’s one thing to balance a quarter on a spindle running at 30,000 RPMs, but that’s nothing compared to our latest feat! Check out what our team was able to balance on this high-speed spindle.
High-Speed Spindle Leaking Coolant
Spindle RepairsWhen a customer noticed their high-speed spindle was noisy and had coolant leaking through the spindle, they called Advanced Spindle Technology to conduct a complete evaluation.
During the disassembly of the GMN HSX 80S high-speed spindle, Advanced Spindle Technology found the coolant jacket around the stator was eroded through. It was clear the coolant jacket needed to be replaced or repaired to get the spindle back into operation. There was also minor contamination found throughout the spindle bearings.
The reasoning behind the faulty spindle was most likely due to normal wear and tear. Spindles are the backbone of machining tools and over time can fail. Having a spindle repair partner like Advanced Spindle Technology that can quickly identify and fix the spindle issues can get your shop back on track – fast!
At the conclusion of the evaluation, a report was supplied to the customer with detailed results and a proposal to get the spindle to “like new” condition. Understanding the work that needs to be completed, the customer instructed AST to repair the spindle.
Once the work was completed and the spindle reassembled, Advanced Spindle Technology completed a series of tests and system checks to ensure the spindle would operate at top performance.
Motorized spindle from SETCO fails due to contamination
UncategorizedMotorized spindle from SETCO fails due to contamination.
The SETCO internal motorized spindle wasn’t performing well and was sent to Advanced Spindle Technology for a complete evaluation. Our technicians completely disassemble the spindle to measure and evaluate the overall condition. Our findings lead us to report the rear bearings failed due to contamination, possibly due to a leaking O-ring.
In order to get this spindle back into operation (and fast), AST performed the following work:
After the re-assembly, a series of tests were run to confirm the spindles “like new” condition.
If you would like to get a quote for your next spindle repair – visit here.
High Frequency Spindle Run-Off
Spindle RepairsWhat do President Lincoln and a spindle have in common?
In this video, we are showing the impressive balancing act of a penny during a spindle run-off. The coin, featuring President Lincoln, sits atop a high-frequency spindle turning at 30,000 rpm and doesn’t budge.
Our instruments prove the spindle is fully powered and actually running at that rate. To show there aren’t any camera tricks, Lloyd, our technician and videographer, picks up the penny to prove it’s not glued.
We hope you enjoyed this fun way we can show our dedication to our work!
Subscribe to our YouTube Channel where you can see all our spindle videos.
How do I know my CNC Spindle is going bad?
InformativeWhile machining equipment has evolved a lot over the past few decades and become both more intuitive and more durable, the fact remains that all moving parts will eventually wear out, which includes the spindle. Once it begins to go bad, you’ll need to invest in premium spindle repair to get things back up and running once more. How do you tell if your spindle is ailing, though? What are the signs to look for so you can head off emergency repairs?
Finish Issues
One sign that your spindle is about to need repairs is if you notice finish issues on machined products. As your spindle wears, you will begin to notice that the finish is not as good on specific axes. For instance, you could have a good finish on the X and Y axes, but a poor quality finish on the Z axis (or any combination thereof).
Spindle Mouth Wear
If you notice wear at the spindle mouth, it is a good sign that you need to invest in repairs. To check for this, you can use a known good toolholder and bluing. Check it on the spindle to see if there are gaps in the bluing transfer. You can also check the runout with a T.I.R. – measure at the spindle and then again at the bench for the identical toolholder. Note that toolholders sticking is also usually a sign of spindle wear and looming repair needs.
Fretting in Toolholders
Check the inside of your toolholders for signs of wear and damage. Fretting is one of the most common and most noticeable types of wear, and is created by the toolholder slipping inside the spindle. Any toolholders with visible fretting should be replaced and if you notice that the replacement develops fretting quickly, it’s an indication that the spindle is the issue.
Vibration
It should go without saying, but any sort of unusual vibration during operation is most likely going to be related to spindle wear and/or damage. Make sure that your spindle is properly lubricated to increase bearing lifespan and prevent vibration (unless your spindle is sealed, of course).
Noise
Unusual noise during operation may be a sign of spindle wear, as well. However, you’ll need to play detective to make sure that the noise is coming from the spindle itself.
Temperature
Finally, temperature is also a means to determine if you need to invest in premium spindle repair. During operation, your spindle should usually remain cool. Some machines do get a little warm, but if the spindle becomes noticeably hot during machine operation, it’s important to have it repaired quickly. If your machine is equipped with a spindle chiller, it may have a temperature alarm that can clue you in to issues.
Premium Spindle Repair
No matter how on the ball you are with maintenance or how vigilant you are about issues, you’ll eventually need to invest in premium spindle repair. At Advanced Spindle Technology, we offer the fastest repairs possible, and return your spindle to you better than new.
Resting Easy in the Spindle Spa
Spindle RepairsThis OKK spindle is resting easy in AST’s Spindle SPA after a complete rebuild. Upon receipt of the spindle, AST discovered the vibration level of the spindle was 20 times the acceptable limit. Additionally, the drawbar and drawbar springs were broken. Adding to the problems, AST found coolant and rust throughout the front and rear bearings.
Not to worry…Advanced Spindle Technology was able to make all the necessary repairs and get it working in “better than new” condition.
GMN Motorized spindle lasted for only 3 months
Spindle RepairsOur latest spindle repair demonstrated how choosing the right spindle repair shop can make all the difference. We received a spindle that only was in service for 3 months after being repaired by another shop. WHY? Because they forgot to grease the front tandem pair of bearings!
We were surprised it lasted 3 months!
Our complete evaluation of this GMN motorized spindle also revealed the rear tandem pair of bearing were excessively greased. Ultimately, the failure was caused by complete improper bearing lubrication.
After all components were cleaned and inspected, bearings and O-rings replaced, motor tested and verified, the spindle was prepped and ready to be shipped out!