Cincinnati Falcon 200 Spindle Repair

The Cincinnati Falcon 200 is a larger CNC turning center.  It it designed with a grease lubricated and belt driven spindle capable of running up to 4,500 rpm.

CHALLENGE

This Cincinnati Falcon 200 spindle arrived with the exterior covered in an oily contaminant.  Upon disassembly, it was noted that the spindle interior was also thoroughly contaminated.  The grease in all the bearings was washed out.  We then measured the critical dimensions and found a few issues.  First, the shaft OD taper and face had extremely high runout, both in assembly and measured on the bare shaft.  Second, the front and rear bearing journals were fretted undersized (Front -14µm, Rear -10µm, ISO = ±5µm).  Lastly, the front and rear journal shoulders both had excessive runout >10µm.  No other significant dimensional deviations were noted.

SOLUTION

The following actions were performed on this Cincinnati Falcon 200 spindle:

• Clean, inspect overall dimensions
• Grind, chrome plate, and finish grind the front and rear bearing journals
• Kiss grind both shoulders
• Kiss grind the shaft OD taper and face
• Replace all bearings, o-rings, and assembly screws

RESULT

After reassembly of all components, adjusting bearing preload, and undergoing break-in and testing procedures, this spindle passed our final quality inspection before being returned to our customer with a 1-year warranty.