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……Read More
Walter DB112005 Spindle Repair
The Walter DB112005 is a dual OD taper grinding spindle. It comes equipped with a grease lubricated and belt driven spindle capable of running up to 10,000 rpm.
Our customer, a large tooling manufacturer, was experiencing a loud, roaring noise and poor part finish with this double-ended grinding spindle. Our evaluation of the spindle showed that one of the two pairs of ceramic bearings had failed due to contamination with grinding swarf. The grease in those bearings was degraded to a dry powder, providing little or no lubrication. We also determined that the wheel hub tapers on both sides had excessive runout.
We replaced both sets of ceramic bearings and improved the runout of both tapers with a kiss grind on one of our own Kellenberger cylindrical grinders, which can hold micron tolerances. Once rebuilt the tapers had less than a micron of run out.
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
Dry grease residue on the side that did not fail catastrophically.
This is the housing from the side that the bearings failed. The black powder is a combination of phenolic cage, contamination and grease. Once the grease deteriorates the balls contact the phenolic cage causing more debris that causes the rolling elements to fail.
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