Category: Spindle Repair

Throughout time, agriculture has remained a staple in economies all over the world. Like any industry, the agricultural sector has been no stranger to industrialization and developing revolutionary technologies to streamline operations and scale to accommodate growing population demand. What once took days of human labor, now only takes hours with the help of new technology and machinery.

However, this increased efficiency brings unique challenges. More machines means more opportunities for machine and spindle failure, which subsequently result in costly downtime. It is important for those in the agricultural industry to employ regular spindle maintenance and repair schedules while introducing groundbreaking technology to their processes.

New Demand

Agricultural demand shares a direct relationship with the global population. After growing by over 76 million in 2017, the world’s population is currently 7.6 billion and continuing to grow with staggering speed. With more mouths to feed and the agricultural industry responsible for supplying all the necessary crops, it’s no surprise that the industry has transformed and introduced new technology to streamline processes and improve efficiency.

New Technology

Advancements in robotics and automated machines have revolutionized the agricultural sector. In many cases, the technological developments have introduced new devices and reduced the number of labor hours required by farmers. An example of this new tech can be seen in the growing popularity of lighter, automated tractors, and machines that improve performance, precision, and efficiency.

Increased demand, and reliance on new machines and technology, means the financial impact of machine failure and downtime also increases. In a time-sensitive industry like agriculture, operational halts leave fields unharvested and unfertilized, directly impacting the bottom line.

Much of this downtime can be reduced, if not prevented, by employing proper spindle maintenance and repair. Contact the knowledgeable professionals at GTI Spindle Technology to learn how agricultural spindle repair and maintenance services can benefit your operations.

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.

One of the leading causes of machine tool failure is imbalance. A spindle can become unbalanced due to a variety of causes, which can result in damage to other components. Spindle imbalance occurs when a spindle’s center of mass is not aligned with its center of rotation, causing the energy to transfer to the tool and work piece. A few causes of imbalance include thermal fluctuation, improper/inattentive maintenance, poor tools, bent or bowed shafts, and occasionally, product build-up.

To fix a spindle that has become unbalanced, the axis of inertia must be restored to nearly-perfect alignment with the axis of rotation. While the effects of imbalance are slightly less noticeable on low-speed machine tools, it is critical that high-speed spindles be balanced to ensure optimal performance and a maximum lifespan.

To fix spindle imbalance, a balancing system is required, specifically one that has a two-plane function. For these tips on correcting spindle imbalance, we will be describing a common balancing system setup that features a tachometer, an accelerometer, and two-plane balancing software with a digital data readout display (i.e. an iPad tablet).

Once you have a setup like this in place, the following tips will help you conduct the balancing process and minimize potential errors:

• Weight Recommendation – Spindles come in a wide range of weight-ratings, some weigh less than 20lbs while others can weigh more than 100lbs. The software will recommend the exact recommended trial and correction weight, based on the estimated rotor/shaft weight.
• Rotation Direction – Ensure that your spindle and software are set for the same rotation direction. If your device is set up for clockwise rotation, it is important that your software is set up to gather data according to clockwise rotation. This is a common error made when balancing machine tools.
• Tachometer Signal – Verify that your tachometer is exhibiting a signal. It is common for tachometers to lose their signal due to being bumped or moved. It is also common for the reflective tape to fall off during the process of balancing, so be sure to monitor tape placement.
• Tachometer and Accelerometer Alignment – The setup of your tachometer and accelerometer is key to the proper balancing of a spindle. Ensure that your tachometer is facing the accelerometers, on the same side, and on the same horizontal or vertical plane.
• Misalignment and Tool Looseness – A spindle that is misaligned or loose is virtually impossible to balance. It is critical that you check for these two factors before attempting to balance a spindle.

The benefits of regularly balancing a spindle include enhanced machine accuracy and efficiency, longer tool life, and increased life of related components such as bearings. Balancing will also decrease the noise and vibration levels created by machine tools during operation.

These are general guidelines for balancing a spindle. For specific spindle balancing needs, contact an experienced professional with the correct equipment and expertise.

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.

Like all moving machine elements, bearings in spindles can fail due to a variety of causes. While normal wear and tear is one of these causes, there are specific points of failure that are more common than others. Before it becomes necessary to repair a spindle due to bearing damage, consider these factors that may lead to spindle bearing failure:

Improper Lubrication:

Lubricant is critical when it comes to spindle performance; it affects maximum operating speed, temperature and vibration levels. Improper lubrication can cause bearing failure in several different ways. The most prevalent lubrication error is using an insufficient amount. This can lead to increased wear due to friction as well as thermal damage due to higher operating temperatures. The resulting damage to bearings can include rolling element deterioration, raceway deterioration, cage fragmentation, and eventually spindle failure.

When it comes to lubrication, here are three things to keep in mind to ensure longer bearing life:

Always use the right type of lubricant: There are many types of bearing lubricant – be sure that you are using the right compatibility and viscosity. Quality is also a significant factor, and a sub-par lubricant can increase the chance of wear in a bearing.

Always use the right amount: An insufficient amount of lubrication can cause damage to your bearings, but too much lubrication can also cause issues. Following lubricant specifications for your machinery will increase the life-span of your bearings.

Always apply lubrication at the right time: Applying lubricant too often or not often enough can lead to bearing failure, even if you are using the right type and amount. Adhering to a lubrication schedule will ensure maximum performance.

Contamination:

The next common source of bearing failure in spindles is contamination. Contamination can be introduced to bearings through various fluids and particulates, dramatically shortening their life span. Two typical sources of contamination include:

Coolant contamination: Using an air hose to blow coolant and away from your equipment can force various particles into the spindle, contaminating the bearings. Misdirected coolant nozzles can also introduce particles into the bearing. Positive pressure purging seals can be a good line of defense against this form of contamination.

Chip and Air Contamination: Air can be one of the most expensive commodities in a manufacturing plant. In an effort to reduce these costs, machines are often programmed to stop air supply when the spindles are not in process.  This is actually a costly mistake. Spindles can operate at very high temperatures, and premature removal of an air hose from a hot spindle can create a vacuum in which contaminates are drawn into the spindle, like solder into a joint.

Chip contamination can also occur when an air hose is disconnected from the spindle and laid into a dirty environment.  Turning the air on and letting it run for approximately five seconds before connecting the hose to your spindle is a good method for eliminating contaminants in the air supply.

Mishandling:

While spindles and their bearings may seem like sturdy pieces of equipment, they are actually sensitive to mishandling. Even the smallest impact can set a spindle up for bearing failure. Things to keep in mind when handling a spindle:

Proper storage: Storage of machinery and parts can be different depending on your equipment. When storing spindles, there are a few notable factors that can affect their performance. Maintaining a low-humidity storage area ensures that condensation does not accumulate. Drastic changes in temperature can also affect spindles and bearings. A dry area that does not fluctuate outside of 65°-120° Fahrenheit is ideal for storage.

In addition to stable temperatures, stable levels of vibration are also important when it comes to storing spindles. Spindles should be stored in areas with very low vibration to ensure maximum performance when they are put into use. All coolant and oil ports in a spindle should be plugged to avoid contamination. Wrapping spindles with oil paper also ensures spindle health during storage.

Spindles that have been sitting stationary on a shelf for an extended period of time are also subject to a phenomenon known as micro-welding. After approximately 3-6 months, the balls within the bearing can “weld” themselves to the raceway, which can lead to spindle failure. This can be avoided by hand rotating your spindle periodically by 1-2 revolutions.

Proper handling/installation: Utmost caution should be used when moving a spindle before installation. Even small impacts, burrs, or nicks can reduce performance and lifespan. When it comes time to install a spindle, it is crucial to use the proper tools in a clean work environment. Any form of shock load to the spindle can lead to brinelling, a condition in which the bearing raceways become impacted. It is recommended that installation, storage, and handling all be handled by professionals.

A spindle is the heart of your machine, and bearings could be considered the heart of the spindle. Keeping your spindles in optimal operating condition is crucial in minimizing downtime. By practicing proper methods for lubrication, avoiding contamination, and improving handling, you can ensure that your spindle will operate at maximum efficiency.

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 repair and rebuild is the heart of what we do at GTI Spindle Technology, and we pride ourselves on being able to handle any spindle that comes through our door. All spindles can be repaired, though the associated cost for some can eclipse that of a brand-new spindle. When this happens, we turn to Peron Spindle for a replacement.

GTI is the exclusive North American reseller for Peron Spindle and we have been working together since 2013. GTI sought a relationship with Peron because of their diverse product line and complete spindle knowledge as well as their high standard of quality craftsmanship.

Peron spindles feature heavily in the aerospace, automotive and OEM sectors where GTI specializes. Peron is known for their high frequency ID grinding spindles utilized in this sector and this type of spindle plays a critical production role for many of GTI’s customers. By providing Peron replacement spindles GTI gets customers back up and running with minimal downtime.

Should customers have an obsolete spindle and replacements are no longer manufactured, GTI and Peron have you covered. Using your existing spindle, Peron will reverse engineer a completely new spindle saving customers time and money having to retrofit or replace machinery. Peron also does not require a set production run to manufacture spindles enabling them to fabricate one-off spindles.

The relationship between GTI and Peron Spindle has saved our customers thousands. Here is one such example. As with any customer, GTI has to understand their situation: their needs versus their wants, their problems and most of all have them trust in our ability to address these issues. We have a spindle design tech that has worked with one such company for over 30 years.

This company has 30 plus machines with GTI repaired spindles. Each machine has a grind spindle and a dresser spindle; Peron has built duplicate replacements for both types of spindles. In order to maintain production, they have always maintained a supply of spare spindles. Spindle life is far from a finite number and it can vary from a few weeks to as much as 2 years. A spindle can always be repaired, it is just a matter of making this cost effective. Some companies will purchase new spindles when the repair cost is more than 50% of a new replacement, while others will allow repair spindles cost to go as high as 75% before replacing.

As repair cost for these spindles increased due to age and other factors, GTI took the initiative to discuss replacing some of the higher cost repairs with new spindles. GTI’s knowledge of the spindles comes from the many repairs we have done and our engineering expertise allowed GTI to approach Peron with spindle specifications for a design that would require no changes to the machines. In going to Peron with specifications that would make the new spindle a direct replacement and getting a quote for replacing those high cost repairs, GTI was in a position to present a clear cost effective proposal.

In this case, GTI did an analysis of some of the high cost spindle repairs to determine which spindles should be replaced. Not only were the most recent cost reviewed, but several years of spindle repair history was taken into consideration. Spindles that had a long history of expensive repairs were candidates for replacement as opposed to a spindle that had only a recent one time high cost repair.

Based on the cost of a new replacement spindle, a dollar figure was assigned that made a spindle repair questionable. GTI provided a list of spindles that fit this criterion and suggested a quantity of spindles to be replaced as well as a cost justification for the replacement. The three main factors to be considered for replacement were a direct replacement spindle, cost of repairs versus new spindles and lost production. Therefore, the cost justification was based on new spindle cost, old spindle repair cost and lost production due to spare spindles not being available. 

A total of four new spindles were purchased and are now in use, manufacturing product alongside the original spindles. Additional new spindles are to be considered as the older spindles become too expensive to repair; some of these spindles are over 25 years old.

Machines are comprised of a whole host of pieces, of which a spindle is the most crucial component. GTI’s relationship with Peron allows us to provide outstanding customer service and supply high quality spindles when repair is not an option.