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Mazak Variaxis 730 Spindle Repair

The Mazak VARIAXIS is a highly versatile line of full, simultaneous 5-axis machining centers that perform multiple and complex curved surface machining on large, heavy workpieces in single setups.

CHALLENGE

Upon initial inspection, the spindle felt very rough with loud bearing noise when rotated by hand.
The actuator and rear of spindle were heavily contaminated, and it appeared that the rotary union had been leaking coolant for some time. The rear roller bearing suffered catastrophic failure. Encoder sensor was damaged and the encoder ring showed wear. The actuator and drawbar had rubbed out, and the rear of the drawbar shaft had severe damage. Further inspection uncovered that the #1 and #2 front bearings were heavily contaminated with coolant. The tooling taper was pockmarked with uneven tool contact. Gripper fingers (collet) showed significant wear.

SOLUTION

This spindle rebuild required the following actions:

Grind, chrome plate, finish-grind BIG Plus 50 taper ID
Replace bearings, Bellevilles, oil line, seals, o-rings, and assembly screws
Customer obtained and provided the following OEM parts:
Rotary union, grippers, encoder, encoder ring, upper drawbar shaft, actuator push plate & ferrules

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.

DETAILED CAUSE OF FAILURE

Tooling taper ID was pockmarked with uneven surface
The rear of spindle showed evidence of coolant leak
Our thorough breakdown and evaluation process includes dismantling every component of the spindle
Worn gripper fingers were replaced with new
Rear roller bearings had failed due to contamination

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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.

Your staff is amazing. I dropped off my spindle at the repair facility and I was met by four guys in the shipping and receiving department and they absolutely understood what I needed for my little woodworking spindle it was fixed properly. Everyone was professional machine is back up and running, it works properly no play, not overheating. The machine now cuts better with less noise. I saw other spindles there from Hubble telescope and an aircraft facility. I knew I was in good hands.

— Scott Masi, Chairman Of Maine

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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News & Events

Northland Tool and Electronics Inc Announces the Acquisition of RMR Spindle Repair, Inc.

WEARE. [26] December 2024 – Northland Tool and Electronics (NTE), one of the original premier spindle repair facilities in the United States, is excited to announce the asset acquisition of RMR Spindle Repair, Inc. (RMR), Belgium WI.