Toyoda FA400 Spindle Repair

Toyoda FA400 Spindle Repair

The Toyoda FA400 is a CNC horizontal machining center.  It comes fitted with an oil mist lubricated and stator driven spindle capable of running up to 14,000 rpm.



CHALLENGE

This spindle arrived at our facility after having been completely disassembled by another spindle rebuilder. In this scenario, it is often extremely difficult to determine the exact cause of failure. Add to that the inability of our customer to provide us with a spindle drawing and parts list and you have a bit of a challenge on your hands, but the technical staff at Northland Tool was up to it.

The rear roller bearing had failed in this Toyoda FA400 spindle, though we also noted that the 125mm front housing bore was worn out of round +8/+25µ (ISO = ±9µ) where one of the front tri-set of angular contact bearings was located. We also noted that the tooling taper ID had been previously plated, and that the chrome was chipping out on the large diameter. The tool retention gripper fingers and the encoder sensor had significant damage, and the customer did not provide various shaft and drawbar keys, nor did they send either half of the rotary union.

 

SOLUTION

We performed a grind, chrome plate, and finish grind of the shaft tooling taper and the front housing bore to address the dimensional deficiencies we noted during our evaluation. After a thorough cleaning of all the other spindle components, we reassembled the spindle with all new bearings, bellevilles, grippers, encoder sensor, keys, seals, o-rings, and assembly screws. Tool retention force was checked and found to be correct.  We advised our customer to replace both sides of the rotary union prior to reinstalling the spindle in the machine.

 

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

  • Housing with ID measurements

  • Area of the housing with fretting damage

  • Chipped chrome in the taper

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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