Spindle issues are a common problem in metalworking environments, but without a spindle that is in adequate working condition, it isn’t possible for manufacturing to continue until it has been repaired. There are a number of issues that could cause a spindle to fail, but determining the specific issue as well as fixing it can sometimes be a challenge. Here is an overview of some common metalworking spindle issues and how to tackle them.
A Spindle That Vibrates Excessively
Spindles are notorious for vibrating excessively, which can be very frustrating, especially when trying to complete a job. Several possible causes include missing or broken tooling inserts, tooling extensions that are too long for the vibrating speed, and even improper lubrication. If your spindle is vibrating excessively, you will likely need to send it to the manufacturer for diagnosis and repair.
A Spindle That Runs Backwards
It might seem alarming if you start using your spindle and realize it’s running backward, but it’s a problem that happens frequently with 3-phase spindle motors with terminal blocks. To fix your spindle and get it running properly, simply switch any two power leads. You must send your spindle in for diagnosis and repair if this doesn’t work.
Common Reasons for Frequent Spindle Issues
There are many common reasons for frequent spindle issues that can be avoided. Here are some of these reasons:
Failure to Follow Manufacturer’s Instructions
All spindles are different, which is why you must learn how to use each one properly. Just because you may have had experience with one type of spindle doesn’t mean that a new one of a different brand is used in the same way. Using a spindle improperly can cause it to fail, so even if you and your team are very busy, you must still take the time to read the instruction manual and learn to use each spindle correctly. If not, you may be unable to use the spindle until it’s been repaired or replaced.
Improper Storage
Spindles must be stored in a protective and proper manner when not in use. Your manufacturer’s manual will explain exactly how to store a spindle that won’t be used for an extended period, but here is a quick reference that applies to all spindles:
- Store in a temperature-controlled environment – If you have invested in backup spindles, storage at temperatures that are too hot or too cold can cause damage to your replacement spindles. Temperatures should be between 65 and 120 degrees Fahrenheit.
- Prevent contamination and corrosion – Empty the coolant from the spindle before storing it and plug up all openings. This ensures no humidity, dirt, or other contaminants can enter the spindle and cause damage.
- Regularly rotate the spindles while in storage – For spindles remaining in storage for a month or longer, spindle rotation should occur about once every two weeks to a month. This prevents the internal metals from touching and redistributes the lubricant.
- Carefully inspect the spindle before reusing – If your spindle has been in storage for over a month, you should thoroughly inspect it before using it. Despite your best efforts to ensure proper storage, the spindle may have sustained damage while in storage.
Failing to Use the Proper Lubricant
You must not only ensure you keep your spindles adequately lubricated, but you must also ensure that you’re using the correct product. Failing to provide lube or use the proper lubricant can result in the failure of a spindle. If you’re unsure what type to use, refer to the manufacturer’s manual.
Manufacturing Material That is Too Hard
Sometimes, the material is too hard and can damage the spindle. While it is possible to process most materials, special techniques must be used when processing harder than normal materials.
Repairing Your Failed Metalworking Spindle
Aside from performing inspections, basic maintenance, and troubleshooting, unless you’re a certified technician, there isn’t much you can do if your spindle requires repair but send it off. While many companies specialize in general spindle repair, it’s best to deal with the manufacturer of your particular spindle to ensure precision. The manufacturer will also use higher quality parts, which will help the spindle work as well as it did originally, or even better in some cases.
Repairing Your Spindle, Step-by-Step
Repairing a spindle is very time-consuming and must be performed strategically. Here is an overview of the step-by-step process:
- The first step in the repair/rebuild process is to thoroughly evaluate the spindle to determine its current condition, and documentation is made. Cleaning is also performed during this step.
- The next step is to disassemble the spindle. This enables the technician to evaluate the tool further to determine what caused its problem. Photos will be taken during this step and provided to the owner after completion.
- The third step in the process is to provide the customer with a quote. This thorough quote consists of notes, pictures, and an explanation of the problem and necessary fixes.
- Once the repair has been approved, the technician will replace the necessary parts and repair the others. The spindle is then cleaned and reassembled.
- The final step of the process is to test out the spindle in an environment that is equivalent to the one it’s regularly used in.
As you can see, there are many different reasons why your spindle may have failed. Regardless of the cause, the repair process is very complicated and time-consuming and must be completed by a professional. This is why it’s best to prevent these problems from occurring in the first place. Of course, all spindles will eventually wear out and need repair or replacement, but the better you maintain them, the fewer episodes of failure and malfunction you’re likely to experience.
