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Author: GTI Staff

  • How the Manufacturing Industry Will Adapt to COVID-19

    While the COVID-19 pandemic isn’t quite behind us, restrictions in several states are beginning to relax and many companies are grappling with how to return to work responsibly. For essential businesses like the manufacturing industry, planning for the future has less to do with bringing workers back to the office and more to do with preventing disruptions from any potential future crisis.

    The economic impact of the coronavirus will likely hit the hospitality, restaurant, and leisure industries the hardest, but manufacturing is far from immune to its effects. Due to supply chain disruptions and concerns about worker safety, companies are scrambling to figure out the best way to move forward so that production can return to normal without leaving themselves vulnerable to another potential wave of infections.

    CNC Machining Will Shoot Through the Roof
    CNC machining has been the preferred method of precision manufacturers for decades. It offers the highest threshold for accuracy, reduces waste, and improves production speed enormously. However, in the age of social distancing, perhaps the most appealing advantage CNC machines provide is the reduction in human labor. While some human presence is essential in every manufacturing setting, reducing the number of essential personnel is the best way to minimize the chance of infection among the remaining staff. While industries like aerospace, pharmaceutical, and automotive already require CNC machinery to meet their rigorous standards, it’s likely that we’ll see more industries with less stringent requirements adopting the high-performance tools to reduce their physical workforce.

    Some Manufacturing Will Move Back to the US
    During the peak of the coronavirus pandemic, supply chain disruptions impacted nearly every industry. From severe shortages in grocery stores of essential goods like toilet paper, to limited supplies of medical equipment, and everything in between, the COVID-19 pandemic painfully illustrated a critical flaw in the US’s dependence on foreign manufacturers. Now it’s clear that one of the critical advantages to overseas production is actually a detrimental weakness. The inexpensive labor force that lured American manufacturers poses a severe threat for future production. Returning some companies to the U.S. certainly has its own upfront cost, but it will likely to be viewed as an acceptable investment to ensure a less fragile supply chain in the future and to reduce the reliance on human labor.

    Independent Repair Companies Will Offset Labor Concerns
    Going forward, manufacturers will have a very high incentive to retain as much flexibility in their labor costs as possible. With some studies estimating that labor represents more than half of all overhead expenses and with so many employees being sent home, the value of having a trusted, third-party repair company has never been higher. For manufactures, utilizing independent spindle repair companies can help fill necessary labor gaps as businesses try to scale down operations.

    To learn how you can strengthen your position in such an unpredictable market, contact the professionals at GTI Spindle Technology today.

    About GTI Spindle Technology
    At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.

     

     

  • How Independent Spindle Repair Companies Can Help During the COVID19 Pandemic

    It’s an understatement to say that the COVID19 (or Coronavirus) pandemic will have a profound and long-lasting impact on the world as we know it. From the way we work, and teach our children, to how we buy food. It’s inevitable that COVID19 will touch upon every facet of our lives–with some estimates predicting it could rob as much as 2 Trillion dollars from the global economy.

    While restaurants, airlines, and the hospitality industry are the worst hit by this catastrophe, manufacturing is far from immune to its effects. Even after the pandemic has subsided and social distancing comes to an end, many companies estimate it will take between three and six months for manufacturing to return to normal. To weather the storm manufacturers should take advantage of every opportunity available to reduce costs and improve efficiency. For manufacturers with CNC machines, utilizing independent spindle repair companies offers significant benefits during such unpredictable times.

    Independent Repair Companies Reduce Labor Costs

    It’s no secret that labor is expensive. A Harvard Business Review study showed that labor expenses typically represent more than 50% of overhead. With so much uncertainty regarding both material supply and consumer demand it’s essential for manufacturers to remain as flexible as possible. Some estimates project that more than 2 million layoffs could result from the pandemic, as companies scramble to reduce labor expenses. For manufactures, utilizing independent spindle repair companies can help fill necessary labor gaps as businesses try to scale down operations.

    Domestic Repair Companies Improve Repair Turnaround Times

    With global supply chains severely disrupted and international borders shutting down, many OEMs are cutoff from their equipment. For manufacturers this can add untold delays for even the most routine spindle repairs. However, a domestic repair company, such as GTI Spindle, can provide quick turnarounds to get manufacturers back into operation significantly faster than foreign OEMs. In fact, many OEMs partner with independent repair companies to provide supplemental repair services in regions that they can’t effectively cover. 

    Companies with Expertise in Vibration Analysis Can Help Manufacturers Go Remote

    Unplanned downtime is one of the most expensive challenges manufacturers face. Some estimates calculate that downtime costs as much as $22,000 a minute in the automotive sector. Vibration analysis tools–as part of a larger predictive maintenance program–offer an invaluable opportunity for manufacturers to reduce downtime and prevent total machine failure. However, these powerful programs offer another unique benefit; they can help manufacturers move more of their staff to remote operations. Independent spindle repair companies, such as GTI Spindle, can seamlessly tie their repair service into an existing predictive maintenance program by providing critical vibration analysis data on all repaired equipment.

    Contact the professionals at GTI Spindle Technology to learn how you can leverage our expertise and spindle repair services to strengthen your position in such an unpredictable market.

    About GTI Spindle Technology

    At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.

  • Why Vibration Monitoring is Key to the Overall Health and Longevity of Your Spindles

    A recent report by Grandview Research suggests that the value of the CNC machinery market will increase to over $100 Billion by 2025. This means that businesses that rely on CNC equipment for fabrication can expect an increase in investment and technology in the CNC world, as well as higher levels of competition when it comes to vendors and services.

    CNC machines offer businesses a highly efficient, minimal labor involved method of manufacturing components. However, the productivity level of these machines is directly related to the overall health and lifespan of the core components, such as spindles. It is estimated that in some industries as much as 26% of the overall downtime of CNC machines is related to spindle failure. This is why monitoring and reacting to machine performance data is key to getting the most out of your equipment.

    What makes up the spindle component?

    The spindle component in a CNC machine is usually made up of a few subcomponents, including rotor shaft, bearings and clamping system, all of which are subject to wear and tear and can lead to total component failure, rendering the entire machine unproductive until the spindle is repaired.

    One of the main reasons for spindle health deterioration over time is the impact of machine process vibrations. Vibration can be caused by a wide range of factors. High loads, unbalanced tools, deteriorating bearings, misalignment. While a certain amount of vibration is accounted for, it’s critical for machine operators to have a tool to visualize when vibration levels become abnormal. Vibration analysis tools provide a remedy before damage is done as repairing the problem after total failure is always far more costly.

    How does vibration sensor technology help extend the spindle’s lifespan?

    Vibration sensor technology has come a long way in the past five years. Many new machines are fitted with real-time vibration sensors; however, older equipment can be retroactively fitted with these devices to enhance an operator’s ability to understand the detailed performance of the machine during uptime. Wireless sensor technology has given us the breakthrough technology to efficiently place high accuracy sensors behind machine doors to quickly collect this important data. These sensors are able to capture a wide range of performance data including the vibration readings when a machine is operating under a very light load, without a load at all, or under very high speeds.

    In addition, data can be collected, and cross analyzed with other data points, such as output productivity, or quality of finish in order to build a database of information to help understand how vibration readings can be used to predict both outputs, quality and the likelihood of machine failure. When this data is captured, we are able to store and analyze it for use with predictive maintenance programs and asset profitability calculations.

    Spindle Balancing Vibration Analysis

    What is the real power of knowing your vibration readings?

    When it comes to vibration readings, knowing the facts is key to the overall productivity of your CNC fleet. Not only does this data help operators make real-time decisions that increase both productivity and quality of output, but it also helps businesses predict if and when spindle components of the machine require repair or spindle balance. This helps to optimize servicing costs associated with keeping the machine running and minimizes the risk of total failure, which heavily impacts the productivity and profitability of the business.

    About GTI Spindle Technology
    At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.

  • 5 Ways to Increase the Lifespan of CNC Machine Spindles

    Increasing CNC Machine Spindle LifeFor manufacturers, the up-time and utilization of their CNC Machines is one of the most important performance indicators and has a huge impact on productivity and profits. Spindles are a critical component of a CNC machine and any issue that arises with this critical piece has the potential to seriously impact the speed at which the machine can complete jobs, or worse can bring the shop floor to a halt.

    1. Don’t Ignore Vibration

    Your machine operators must react quickly at the first sign of abnormal vibrations. This is a tell-tale sign that there is an issue with the overall condition of the spindle, or that there is an alignment issue that needs to be addressed. If your technicians notice this, or if your machine readings indicate that vibration levels are not normal then immediately cease usage of the machine and contact a qualified technician to inspect and repair the fault. Working with independent spindle repair companies with an expertise in vibration analysis is another great way to ensure you’re utilizing this valuable metric to its fullest.

    1. Review Temperature Readings

    Any increase beyond the normal operating temperature is an indicator that something is wrong. If this is the case, it is essential to stop the machine for inspection and maintenance. Common causes of spindle overheating include coolant component failure, improper lubrication levels, or component grinding. Make sure your technicians are familiar with the correct temperature guidelines for their specific brand of spindle and the exact operating conditions they are using it in.

    1. Utilize Sensor Data

    CNC Machine technology has come a long way over the years. Many modern machines are designed with sensor devices that can collect real-time data about machine performance as well as the condition and performance of specific components of the machine. This data can be used to predict when a failure is likely to occur and allow for a quick response by service technicians to ensure that any damage to the spindle and other key components are minimized. Utilizing third-party IoT enabled devices as part of a predictive maintenance plan is a great way to keep up to date on your machine’s overall health.

    1. Routinely Check Surface Finish

    By routinely checking the finish of machined parts you will glean insights into the overall health of your spindle and CNC machine. If you notice a degradation in the quality of the products’ finish, chatter, size fluctuations or a decrease in tool life, then this can indicate there is an issue with the spindle that needs to be investigated. Acting quickly will minimize the risk of causing further damage to the spindle.

    1. Optimizing Speeds

    Finding the right balance when it comes to production speeds can be challenging, but it also has one of the biggest impacts on the lifespan of your spindle. Manufacturers need to consider the benefit that increased production speed has on their outputs, but they should also consider the effect that it has on the overall cost of repairing the CNC machine, and the associated costs of downtime.

    To learn more about how you can extend your spindle life or to schedule a professional repair, contact GTI Spindle Technology today.

    About GTI Spindle Technology
    At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.

  • How to Prevent Spindle Failure

    In high-end manufacturing, any machine tool with moving parts will inevitably need to be repaired or replaced. If the machine is improperly maintained, usage over time can cause wear in to critical components. Damaged spindles negatively affect machine performance and can hinder other key systems. It’s essential to catch spindle wear and damage early and conduct necessary repairs before equipment reaches the point of total failure. Fortunately, there are some steps you can take to optimize your machine’s health and extend its usable life.

    Proper Staff Training

    One of the best ways to keep your equipment in top condition is to ensure it is being used correctly. Operational habits have a significant impact on machine health and performance. Incorrect machine settings such as improper feed rate, excessive loads, improper electrical settings, improper belt tension, lubricant contamination and improper lube rates can all cause unnecessary wear and/or damages to the equipment. Ensuring that your machine operators have read the equipment manuals and are following standard operating protocol will significantly extend the life of your spindles.

    Monitor Your Machine’s Bearings

    Spindle Bearings are one of the most common points of failure within a spindle. When bearings begin to fail, the machine’s overall performance suffers, and it often causes problems in other parts of the equipment. To extend the life of your bearings, train your staff to spot the most common causes of failure.

    Contamination: Contaminants can find their way into bearings through many paths. One of the most common sources of contamination is a misdirected part coolant nozzle. High pressure air guns are another common source of contamination. Running positive air pressure/air purge for 30 to 60-minutes after shutting down equipment along with conducting a visual examination of the nozzle’s direction is a great way to prevent contamination.

    Overload: Overload is the result of excessive forces placed on a spindle during operation. It is often caused by maintenance errors, improper feed rates, and incorrect belt tension. When a machine operates with an overload, excessive friction can cause overheating and lead to significant damage. Training your staff to adhere to the correct load and speed ratings for your specific spindle is the best way to avoid overload.

    Imbalance: Spindle imbalance is usually caused by using unbalanced tooling. The use of unbalanced tooling significantly reduces the precision of spindle and causes damage to the spindle bearings and other critical components. Make sure all your tools and spindles have a regular balancing schedule to improve lifespan and performance.

    Drawbar retention force: When the drawbar springs or Belleville washers’ fatigue and wear over the course of time and use, they lose their retention force which can cause chatter and undue wear on the tools in use. Periodically check tool retention with a retention force gauge replace defective drawbar components as necessary.

    VibePro Spindle Vibration Analysis System

    Use Predictive Maintenance Data

    Utilizing predictive maintenance data can significantly improve your machine maintenance program. We have access to predictive maintenance data acquired by IIoT enabled devices that provide detailed insights into the spindle lifecycle. Vibration analysis is a very popular tool to diagnose a variety of spindle issues including imbalance, bearing issues, and looseness within rotating machinery. A vibration monitoring system can be temporarily mounted on equipment for periodic checks or it can be permanently mounted to receive real-time machine-health updates.

    To learn more about how you can extend your spindle life or to schedule a professional repair, contact GTI Spindle Technology today.

    About GTI Spindle Technology
    At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.

  • Spindle Maintenance Tips for 2020

    Often manufacturers have an “Out of sight, out of mind” approach to spindle maintenance that can result in both costly repairs and production delays. Studies show that unexpected downtime can cost as much as $100,000 per hour. Just like any machine, it’s essential to understand the specific warning signs of your spindles and how to maintain them properly to extend the life of your equipment. Spindles are the heart of the machine, so the time required to add small checks and schedule preventive maintenance is well worth it to ensure an increase in productivity.

    Understand the Specifics of Your Machine
    Proper care is dictated by the type of spindle you’re using and the specific application. Extending spindle life requires a proper understanding of your component. The user needs to be versed on the ins and outs of the spindle they’re using as well as the specific applications. Despite the similarities in external design, typically spindles are built with the application in mind. Internal components, such as the number of bearings, the angle of the bearings, and the preload are developed for each machining application. As simple as it may sound, reading the manual to understand the specifications of your spindle is one of the best ways to learn the guidelines of how to use your equipment. With the spindle tucked away in the machine and out of reach of most operators, it’s essential for technicians to be intentional about their spindle maintenance program.

    Defer to Specialized Spindle Repair Companies
    Speaking to OEM’s or a trusted repair company to confirm the specifics of your machine’s operational circumstances can make a huge impact on the life of your spindle. Independent repair companies can draw from their experience repairing spindles in a variety of industries under vastly different conditions to provide guidelines that you might not be aware of. Companies with expertise in predictive maintenance software have a wealth of information ranging from vibration analysis to thermography data that can be utilized to more accurately track trends over time and make predictions about equipment in similar circumstances. Many OEM’s partner with premium spindle repair companies to provide a wider service area, better response times, and handle custom equipment repairs and rebuilds.

    Run a Spindle Warm-Up Program
    An elevated operating temperature is usually an indicator of spindle issues. One of the best ways to check in on the health of your spindles is to start every shift with a spindle warm-up program. Measuring the temperature of the machine after the warmup cycle is necessary to establish a baseline. If possible, it is always a good idea to measure the temperature of the bearings on the front housing. If it runs hot that is usually indicative of a problem. It is essential to make sure the cooling mechanisms are operating correctly, whether the spindle is cooled through compressed air, liquid, or a fan. Running a spindle warm-up program is a great way to keep an eye on the health of your most valuable asset.

    Ensure Proper Machine Load
    Another way to prevent spindle failure is by making sure the load on the controller is normal. Many machines allow you to define the spindle load condition for specific tools. This safety feature will stop the machine if the limit is reached for the tool in use. To use this function correctly, operators need to verify that the proper settings are implemented to keep overload from occurring. Machining something like titanium with heavy loads can put a lot of stress on a spindle. Make sure the spindle is qualified to perform such operations. Proper machine use and consistent day-to-day care make all the difference when it comes to spindle life. Spindle operators should be aware of machine specifications and run their equipment accordingly.

    To learn more about improving spindle life or to schedule a high-quality repair contact the professionals at GTI Spindle today!

    About GTI Spindle Technology
    At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.

  • Why High-Quality Spindle Repair is Essential to CNC Manufacturers

    Spindle Repair ServicesComputer numerical control (CNC) machines are used extensively in manufacturing to automate many processes that would otherwise be performed manually. As a result, CNC driven machines increase productivity, reduce waste, and even minimize the risk of human error. However, due to the high degree of precision that CNC machines achieve, every piece of the equipment must be maintained to the highest standard. That’s why CNC manufacturers turn to independent spindle repair companies to get the most out of their equipment.

    The Tolerances are Tight
    The industry-standard tolerance for CNC machines is +/- 0.005″, but some industries require even tighter tolerances. For many manufacturers, it’s not unusual to machine parts with tolerances of +/- 0.002″. As a frame of reference, an average piece of paper is about 0.003″ thick. To ensure production accuracy within the thickness of a piece of paper every part of the equipment has to be finely tuned and professionally maintained. Lubrication, debris, vibration, and moisture issues can all damage spindles and reduce the efficiency of the CNC machine over time and diminish the accuracy in the short term. For industries with especially stringent tolerances and high stakes (such as aerospace manufacturing), ensuring consistency literally saves lives. GTI holds tolerances of 0.0001″ or better on all repairs that we conduct.

    The Cost of Disruption is Prohibitive
    As with all manufacturing, the cost of breakdowns in CNC production can be enormous. From repair expenses to ballooning labor fees and lost productivity. There is nothing more terrifying to a manufacturer than unplanned downtime. While this is just as true on the final product assembly line, the fact remains that in CNC manufacturing the expectations are higher, and the cost of the equipment is significant. CNC machines are state of the art and having one out of operation due to a broken spindle represents a significant investment loss. Professional, independent spindle repair companies can often diagnose and fix problems in machining, grinding, turning, and boring spindles faster than OEMs and get the manufacturer back into operation. 

    Technology Advances Faster Than Manufacturers Can Keep Up
    Studies show that CNC machining is on the rise with some predicting the overall CNC market to reach 100 billion by 2025. As this equipment evolves and becomes more integrated with IoT enabled devices it will be essential for manufacturers to have spindle repair experts to stay apprised of developments. Independent spindle repair companies with an expertise in predictive maintenance programs such as vibration analysis and thermography will be vital to stay competitive in an ever-evolving global marketplace.

    For quick and professional spindle repair for all major brands of CNC machines contact the professionals at GTI Spindle Technology today.

    About GTI Spindle Technology
    At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.

  • Why Independent Spindle Repair is Vital to the Aerospace Industry

    It’s undeniable that the aerospace industry is rapidly changing. With global shortages in new aircraft supply and economic uncertainties on the horizon, independent spindle repair companies can provide high-quality services to extend the life of your machines and help you stay competitive.

    There is a Critical Shortage of Planes
    Plane orders are up, but the supply is down. Some airlines have begun to experience severe route disruption as a result of the lack of available airplanes to purchase. Globally, the cost of purchasing and leasing equipment has risen exponentially. Utilizing independent spindle repair companies to extend the usable life of your machines is a proven way to get the most from your investment. Studies show that spindles last significantly longer when properly repaired or rebuilt and save 40% of the cost of a replacement.

    The Aerospace Market is Facing a Downturn
    The manufacturing industry is facing a great deal of economic uncertainty, and aerospace is far from immune. Some studies show there may be a downturn ahead for the entire business. Professional spindle rebuilds represent a smaller investment than full equipment replacements. This leaves you less exposed should demand suddenly drop. The right spindle repair company can handle the full capabilities of the aerospace industry including but not limited to maintenance, repair, rebuilds, and upgrades.

    When revenue is uncertain, having a trusted spindle repair technician can help you stay competitive, meet exact specifications, and integrate repairs into your preventative maintenance program. Professional facilities are capable of addressing the ongoing challenges that many aerospace customers face while trying to get ahead.

    Precision is Paramount
    While high-quality repair services are essential in any industry that relies on spindles, the fact remains that in the aviation business lives depend on precise machining. Utilizing a spindle repair company that ensures better than new rebuilds and has an expertise in vibration analysis is the best way to make sure you’re exceeding the expectations and regulations demanded in such a complex industry.

    For aerospace spindle repair that utilizes the most cutting-edge technology and meets the latest industry standards and ISO specifications, contact the professionals at GTI Spindle today!

    About GTI Spindle Technology
    At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.

  • How to Prevent Spindle Bearing Failure

    Anyone that operates high-capacity manufacturing spindles understands that spindle bearing health is critical to the successful operation of a machine. As bearings wear and deteriorate, the performance of the spindle will suffer. If the problem isn’t corrected, then total failure is inevitable. Common causes of bearing failure include poor storage and handling, contamination, overload, incorrect preload, imbalance, and drawbar mechanism failure. Understanding the common causes of bearing failure is essential to counteracting them and extending the life of your spindle.

    Bearing Storage

    Unused spindles should be kept clean and be rotated periodically to prevent bearings from resting in the same position. When spindles are left to sit for long periods of time the consistent pressure on portions of the bearings can cause flat spots to form. Misshapen bearings are a common cause of spindle failure.

    Before mounting a new bearing, check the bearing housing and shaft to make sure they are clean and free from damage. Use the tables supplied by the bearing manufacturer to ensure that the correct amount of clearance will be present when the bearing is installed. When replacing old bearings, make sure you are using new ones that are identical to the manufacturer supplied models, and don’t remove the bearing from its wrapping until it’s time to install.

    Contamination

    Spindle Failure Bearing Contamination
    Contaminated Spidle Bearing

    Bearing contamination is one of the most common causes of bearing failure and can be caused by airborne contaminants from compressed air systems, ingress through worn bearing seals, improper or contaminated lubricant, metal debris from internal component failure, and poor installation.

    For air-oil lubrication systems, you should only ever use clean, dry, compressed air. Compressor filters should be changed regularly, and an annual compressor air system audit can also help prevent contamination. Seals need to be properly installed to manufacturer specifications to reduce ingress of chips and debris from the machining process. Preventing debris from building up on seals will also extend their usable life as well as reduce bearing contamination.

    All spindle, bearing and seal assemblies should be carried out in a cleanroom to prevent contamination, and an expert should be consulted regarding lubrication.

    Overload and Preload

    Bearing overload can be caused by a variety of external forces, such as feed rate, excessive preload, improperly sized bearings, and improper belt tension. Overloading increases heat which can damage the bearing race.

    When a bearing is installed in the spindle, proper preload is vital for good machine performance and to ensure a long bearing life. When the preload is too low, the bearings will skid or skip, whereas excessive preload causes undue friction which leads to excessive heat. Both will lead to poor product quality. Always pay close attention to the operating specifications provided by the machine tool manufacturer.

    Imbalance

    Imbalance is not only one of the most common problems encountered in high-speed spindles, but it is often the source of many other major problems such as looseness and bearing failure. Imbalance in a spindle can be caused by many influences such as poor drawbar retention, continual pressure on the same points within the tool holder, poor bearing installation, and tool holder or tool imbalance.

    Special measuring tools and training are required to detect and correct imbalance. There are industry standard vibration levels to help identify imbalance problems. Imbalance can be corrected in the field with balancing tools and proper training. A best practice for helping prevent imbalance is to require all spindles coming from independent spindle repair companies to arrive with a certificate of balance included.

    Drawbar Mechanisms

    As the retention force of your machine’s drawbar decreases over time, it will experience chatter, repeatability problems, and degradation of tool life and surface finish. It’s advised that you check the drawbar force at least every two months using a commercially available mechanical gauge. A good time to check drawbar force is whenever you collect your vibration data. You can record and trend drawbar force as a companion to your vibration and temperature levels.

    Specified drawbar force will differ with different machines and spindles; be sure you know your manufacturers’ specifications. While a drawbar repair typically costs hundreds of dollars if caught early, drawbar failure can cost thousands when you consider the effects of a spindle crash, spindle grinding, and lost productivity due to downtime.

    To get the most out of your spindle bearings, and reduce breakdowns, contact the professionals at GTI Spindle Technology today.

    About GTI Spindle Technology
    At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.

  • Train Your Staff in Proper Spindle Maintenance

    Staff Training Spindle MaintenanceFor years many maintenance technicians would wait until a spindle seized completely before taking action, and some would only find out a spindle is failing when the QA department decided to scrap the previous production run due to manufacturing defects. This kind of reactive maintenance approach can cost valuable time and tens of thousands of dollars in labor, material, and repair costs. It’s also detrimental to the long-term health of the machine.

    Fortunately, thanks to advances in predictive maintenance, and our decades of experience in high-tech spindle repair, we’ve developed various methods of monitoring machine health that can prevent breakdowns from happening in the first place and extend the life of your machines.

    Proper Documentation is Essential
    The value of proper training cannot be overstated. However, it’s not enough to train on how to perform basic spindle maintenance–you must also train your staff on why they’re performing the maintenance in the first place. The first step to knowing what’s going to happen is to observe what has already happened. This is why proper and detailed documentation of machine health is so essential.

    Start by devising a plan. What skills are essential to maintain your most important equipment? Prioritize operation-critical machines first and expand incrementally. Utilize a third-party spindle repair service to make sure your staff is staying apprised of the latest technology and techniques. Ask your staff what skills they are most lacking. Having your entire maintenance team involved in the conversation is the best way to convey the importance of proper, continuous training.

    Stop, Look, and Listen
    Your machine operators are your first line of defense against early machine death. Ensuring that the crew members who interact with the spindles on a daily basis know the warning signs of machine health problems is essential to stay ahead of breakdowns. Scheduling regular visual inspections and utilizing checklists of high-priority areas, is a great way to streamline the inspection process. Ensure your personnel understand what each of the machine’s gauges means and when a readout suggests trouble. Every piece of equipment has acceptable operating parameters for oil level, temperature, pressure, etc., and if a machine is running outside those limits it can be a major red flag.

    Train your operators to know what good machines sound like. Most people understand that grinding, squeaking and other irregular noises are indicators of a problem, but knowing what kind of problem these sounds suggest isn’t as common knowledge. For the record, these noises are all indicative of damaged bearings. Leaks or debris build-up around seals should be caught quickly, but often go ignored when machine operators don’t designate time to inspect the equipment. We recommend training your staff to be familiar with the guidelines below for proper spindle installation and inspection.

    PROPER SPINDLE INSTALLATION OVERVIEW

    • Trim Balance
    • Vibration Baseline
    • Blow out debris lube lines
    • Inspect tool retention
    • Alignment and Runout baseline
    • Monitor Temperature
    • Belt tension and transmitted vibration

    SPINDLE/MACHINE INSPECTION

    • Coolant Temperature and Flow
    • Spindle Operating Temperature
    • Vibration Baseline (balance
    • alignment and bearings)
    • Lube flow and settings (except
    • for grease spindles)
    • Air purge setting
    • Drawbar tooling retention
    • Tooling/taper runout and fit

    We understand that manufacturing floors are busy places but ensuring that your team has enough time to stop, look, and listen to their equipment can save tens-of-thousands of dollars in the long-run.

    Utilize Vibration Analysis
    Utilizing vibration analysis programs is one of the most important things you can do to stay competitive. While the algorithms in these smart programs are impressive, they are nothing on their own. Proper vibration analysis, just like all tools, requires insight and experience to get the best results. Your staff must understand which metrics are relevant to your equipment and know what the data means to make informed decisions. The best preventative maintenance programs rely on the staff members’ insight and training to work in tandem with the software. Vibration data starts with a baseline measurement and tracks trends over time to detect problems. Properly trained maintenance staff should be aware of the proper data collection protocols below.

    • Always measure at the same speed and the same load.
    • Know how to set up the optimal conditions for measurement.
    • Conduct monthly data collection during a maintenance shut down or shift change.
    • Keep machine measurement routes short and easy to finish.
    • For most spindles, a single measurement point per spindle will give you a good trend.
    • Data can be collected from permanently mounted vibration sensors.

    Once a vibration analysis program is established other data points, such as temperature or lubrication, can be utilized to provide even more accurate predictions.

    When you do send your equipment to a third-party spindle repair provider, ensure you’re using a company that can provide a vibration certification report. If your installed vibration readings are significantly different from the shop report, then there could be other components in the system that are contributing to the vibration problems.

    To get the most out of your machines, and make breakdowns a thing of the past, contact the professionals at GTI Spindle Technology today.

    About GTI Spindle Technology
    At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.