Takisawa MAC-V1E Contaminated bearings, a damaged tool holder & a crash



CHALLENGE

Takisawa MAC-V1E, 6,000 RPM, permanent grease bearing lubrication, belt driven

Contaminated bearings, a damaged tool holder & a crash.

We usually ask our customer to send us a tool holder with their milling spindles. What we are really looking for is their retention knob (aka pull stud.) It’s just easier to ask for a tool holder because the two components are typically already assembled to one another.

We ask for the customer’s retention knob because we aren’t just swapping out spindle bearings, we are performing a comprehensive analysis and rebuild of each spindle we receive at our facility. Despite having a large collection of tool holders and a variety of specialty tool gaging equipment, we can never expect to have every retention knob configuration available on the market. If we use one of our own retention knobs to check your tool retention force (incoming or outgoing), or to insure that the drawbar is actuating correctly, we will not get the same results as we would using your particular knob.

When we examined this 1990’s era CNC drill/tap milling spindle on arrival, we noticed that the ID of the tooling taper was worn with some damaged areas. At our request, the customer had provided a retention knob attached to a tool holder which was scarred by a number of deep gouges. Add to that the severely damaged drive dogs, and it was easy to see that not only had the spindle been crashed, but that the customer had been beating up the spindle taper by continuing to use the damaged tool holder(s). Finally, on disassembly we found that the grease in the spindle bearings had been seriously degraded by contamination with coolant.

 

SOLUTION

Our first step in this rebuild was to kiss grind the tooling taper ID (the wear & damage were not bad enough to warrant a full grind/plate/grind). We also manufactured a new set of drive dogs for installation onto the spindle shaft. We then reassembled the spindle with all new bearings, Bellevilles & assembly screws, setting the proper bearing preload & testing for proper drawbar function. Finally, we test ran the spindle for six hours to break in the new bearing grease while recording the thermal & vibration characteristics.

DETAILED CAUSE OF FAILURE

  • Spindle completely disassembled and read for evaluation

  • Contamination in the bearings

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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 Sandy, Louis and your outstanding crew for helping us get back into production.

Dan Eaton, Taylor Metalworks

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.

Northland Customer

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 

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