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DMG 635 Spindle Repair

DMG 635 Spindle Repair

This spindle was running at 6,000 rpm when it “suddenly got real loud and smoked!”. This spindle can run up to 8,000 rpm max, and our customer occasionally runs at 8k but mostly at 6k rpm. In the past they replaced the spindle 5 times from the OEM and it has only lasted “about 7 months on average”. (DMG gave them “a couple” at no charge). They were told, by DMG, that coolant was getting in the spindle and washing out the grease. We asked, and the spindle does have air purge, which they do use. I asked him if they had a coalescent filter in line and they didn’t believe so-but he will check as he told me that “come to think of it, sometimes when they spray air out of the compressor water comes out like a hose!” I also suggested he check and see if the air purge goes off when the spindle is off and suggested that if it does, they should see about setting it so the air purge stays on for a 1/2 hour after the spindle is turned off. This is was RUSH REPAIR due to a MACHINE DOWN.

After discussions with our customer we decided to improve the spindle design by incorporating a bearing compliment that is more robust than what came with it from DMG.



CHALLENGE

  • Spindle was seized incoming
  • #1 and #2 bearings had catastrophic failures
  • O-rings were worn

 

SOLUTION

The following actions were performed on this DMG 635 spindle:

  • Clean, inspect overall dimensions.
  • Replace all bolts, o-rings, and bellevilles
  • Due to the frequent failures of this spindle and the cause of failure identified during the evaluation we have determined a change in the bearing assembly will increase spindle life. We replaced the bearing compliment that increases the ridigity of the entire spindle assembly.

 

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.

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More Case Studies

Repair History - Here are examples of similar spindle repairs that may contain additional information that will help you. If you have additional questions, please contact us.

I really didn’t expect this; You guys really pulled it off! My many thanks to your outstanding crew for helping us get back into production.
— Dan Eaton, Taylor Metalworks
Its great not to be sending spindles out on a regular basis since you addressed my problems, but I know they will still be coming sooner or later. Never a problem when we get them back , run better than new. Hope everything is ok there. Please tell everyone there that we here appreciate everything that you do to keep us up and running and the quick turnarounds. Have delt with the rest now deal with the best. Have a great week end and up and coming holiday.
— Northland Customer
Thank you NTE just received spindle today and WOW ! what a nice job. Can’t wait to use it. Thank the Northland team for us for a job well done 
— Northland Customer
Both of the spindles that you repaired are on the machines and running great. We don’t have any spares for those grinders. We probably will not be purchasing a spare, as you have been able to turn around the repairs quickly and the price of a spare is cost prohibitive.
— Northland Customer
I am writing to thank Northland Tool for going the extra mile and saving my company from expensive machine downtime and expensive repairs. We have always sent our Chiron spindles for repair as a shaft with bearings. None of our previous rebuilders pointed out the bearing fretting or the fact that the housing in the machine was out of tolerance and causing premature failure to the spindles. After Northland fixed the housings the spindles have never sounded as good or run as well! Great job guys!
— Northland Customer
The detailed cause of failure reports and the expert technical advice that Northland Tool provides is bar none the best I have ever seen. We struggled to keep two of our large our milling spindles running for longer than 6 to 12 months. Northland Tools evaluation showed that the hydraulic nuts were not holding the assembly together causing premature spindle failure. We discussed this in detail and mutually decided to modify the spindle shaft to prevent this from occurring again. The first spindle we performed this on is still in the machine running like new after 3 years. That’s over three times the life of previous repairs and it’s still going strong. Easily over $40,000.00 of savings so far on that one machine and counting.
— Northland Customer
Your people go above and beyond the call of duty when it comes to spindle repair. When we had difficulty with the spindle installation and we were able to talk directly to a spindle technician that helped us troubleshoot the issue it helped us out of a bind. We have sent several spindles to you and have nothing but great things to say.
— Northland Customer
Thank you for your attention with my quick turn spindle repair. Your status updates allowed me to plan around machine downtime and I now know that you deliver on your promises. In the past other spindle repair vendors talked a big game and consistently failed to deliver. You not only delivered my spindle before the due date but you kept me informed throughout the entire repair process.
— Northland Customer
You performed a miracle with my BIG PLUS spindle. After crashing the spindle severely damaging the taper we found that a replacement spindle was not only cost prohibitive but had a long delivery. Your repair was a fraction of the cost of new and you never would know that the spindle was damaged to the extent it was.
— Northland Customer
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