Our customer’s lathe spindle arrived covered in dried coolant residue. Coolant contamination had completely washed out the grease from the front pair of angular contact bearings and the rear roller bearing. At some point the rear bearing cage had disintegrated, spilling the rolling elements into the spindle housing and distributing a fine black powder throughout the spindle interior. Needless to say, the front pair fared no better. Now provided with freedom of radial & axial movement, the spindle shaft rubbed out on the front labyrinth. We also noted severe wear on the timing pulley, in the tooling pilot & on the shaft face. Although there was light fretting on the shaft from the bearings once the lubrication had disappeared, there were no significant dimensional deviations found on the shaft journals or in the housing bores.
We first performed a kiss grind on the shaft face to alleviate the excess runout, and we machined out the rubout damage to the front labyrinth. We replaced the bearings, o-rings and assembly hardware. Our customer declined our recommendations to replace the timing pulley and to grind, chrome plate and finish grind the shaft tooling pilot. According to our standard break-in procedure, we ran in this spindle at progressively increasing speeds for a total of eight hours while checking the vibration signature & thermal signature and shipped it to our customer within three business days as an expedited repair.
These are the angular contact bearings that carry the axial loads applied to the spindle. As you can see the ball cages have been compromised and the bearings have deteriorated. This resulted in axial movement of the spindle shaft.
These are the rolling elements of the rear roller bearing as they were found upon disassembly. This is the reason the spindle no longer rotated.
This is a good representation of a bearing fretting the spindle shaft. The darkened areas are where the bearings inner race was seated. What you see is the oxidation of the material that has been removed from the shaft.
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I really didn’t expect this; You guys really pulled it off! My many thanks to Sandy, Louis and your outstanding crew for helping us get back into production.
Lou all in all everything is running good. Just had a call from Sandy just the other day, its funny great minds think alike. 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.
Thank you Debbie 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
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.
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!
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.
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.
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.
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.
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…