Catastrophic bearing failure was the main cause of this spindle malfunction Continue reading to learn how Northland Tool performed this repair and converted a Weiss GHK 176239 spindle from grease-injected to permanent grease lubrication……Read More
Cincinnati Milacron Magnum 800 Spindle Repair
The Cincinnati Milacron Magnum 800 is a CNC horizontal machining center. It comes equipped with a 50 HP spindle capable of running up to 6,500 rpm with a CAT 50 tool holder.
Our customer experienced a crash with their machine, causing damage to the interior of the spindle, as well as where it made contact with the workpiece.
Dimensional analysis revealed that critical components were out of spec. The tooling taper ID measured with severe runout of >50µ. The #2 bearing had started to weld to the shaft, which caused the surface to become uneven and resulted in damage to all of the journals as it was pressed off the length of the shaft.
All of the interior bearings had become severely contaminated with black sludge – a mixture of lubricant, coolant, and material swarf. The gear began to heavily fret on the shaft causing a significant difference of >70µ clearance.
All components were thoroughly cleaned and refurbished. This repair required a full replacement of new bearings, bolts, o-rings and seal, and Belleville washers, and a gear was sent to a requalifying facility to be refurbished.
This repair required significant precision grinding work to bring critical dimensions back to OEM spec. A grind-chrome plate-finish grind process was performed on the three 100mm bearing journals, CAT50 ID taper, and the 90mm surface where the gear is located on the shaft. Additional light grinding was performed on the shaft nose OD to address minor cosmetic damage.
After performing all dimensional work, the spindle entered the final stages of our repair process:
- Adjust bearing preload
- Reassemble entire spindle
- Balance shaft
- Break-in procedure
- Pass quality control inspection
Every Northland Tool repair is backed by a 1-year warranty.
DETAILED CAUSE OF FAILURE
Evidence showing where the tool-holding end of the spindle made contact when the machine crashed.
Marred surface of inner race of bearings caused fretting along journals as the ring was being pressed off the shaft.
Fretting on the shaft where damaged inner race made contact along the length of the shaft.
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