how to determine if your spindles need to be requalified

 

All spindle tapers deteriorate with use.  The process occurs almost naturally.

  • The normal working action of the tool causes the large end of the spindle taper to bell mouth.

  • Chips embedded in the sidewall of the spindle cause the tool holder to run eccentric.

  • A worn tool holder on a new machine creates an irregular wear pattern based on the worn tool holder.

 SYMPTOMS OF A WORN SPINDLE:

  •      Loss of accuracy due to tool run out.

  •      Rough surface finishes and excessive manual rework.

  •      Breakage and chipping of carbide tools.

  •      Tool chatter that prevents attaining book-value performance.           

  •      Climb cutting produces excessive machine chatter.

  •      Tools hanging up in the spindle.

  •      Boring bars do not repeat when removed from the spindle.

  •      Brown rust (fretting)  marks on the tool holder taper.  

CHECK FOR YOURSELF:

A quick inspection and test can confirm the need for requalifying your spindle.   Visually inspect the spindle for chip marks in the taper.  An abundance of small indentations usually means chips have caused a bell-mouth condition.  Use a new tool holder to check the extent of the bell-mouth.  Apply a small amount of HI SPOT  Blue Dykem brand to the tool holder taper.  Insert the tool holder into the spindle using the machine's retention system and allow to sit for approximately two minutes.  Pull the holder and examine the taper.  A light blue haze indicates good contact (the Dykem has been squeezed thin).  Dark blue indicates areas of no contact.  Read the wear on bluing as:

  • Even contact - A properly ground spindle.

  • Spotty contact - Chips embedded inside spindle taper.

  • Upper spindle contact - Bell-mouthing.

  • Opposite side & opposite end contact - Likely the machine has been crashed.  (Indicates an out-of-round spindle.)

A GOOD RULE OF THUMB: IT TAKES 50% CONTACT OF THE AVAILABLE SURFACE OF THE TOOL HOLDER TO INSURE COAXIALITY, AND IT TAKES 90% CONTACT TO TRANSFER FULL LOAD HORSEPOWER.     

        

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Copyright 2016 Certified Spindle Preparation, Inc.  All rights reserved.  This material may not be duplicated for any profit-driven enterprise.
Disclaimer:  We make no warranties as to the results to be obtained from the use of this information.  Always defer to the wisdom of the machine manufacturer who understands exactly what has been engineered into their system.

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