Reengineered Not Just Repaired:
We service all Fadal Spindles - ALL RPMS and ALL lubrication
systems:
Our spindles replacements are more than just a "Spindle In A
Box"... We provide much more!
- Simple Step By Step Instructions
- Drawbar Included
- Seal Kit Included
- Precision Balanced
- Complete Run-In (until an equilibrium temperature is reached at the
maximum operating speed.)
Total Engineering Support!
Here's
four key examples of the Total Support our customers
receive:
Diagnoses - Direct help in determining if you
really do need to replace the spindle. When working with
engineers that design the machine, we can help determine if
there's other elements in the spindle system that also need to be
addressed before replacing a spindle.
Documentation - We provide very simple and
concise, step by step instructions on how to install and get
your replacement spindle in and running. With our
documentation we also include Preventative Maintenance tips to
help avoid future failures and extend the life of your replacement spindle..
Warranty - Just like "the old days", we value our
relationship with each and every customer. We are driven by
fairness and committed to your satisfaction. Click on the
About Us page to learn about what guides us today.
Support - It's with our engineering knowledge
that you are getting the absolute
best product support possible at installation and beyond.
The spindle is one of the most important aspects of the machine.
Why buy a spindle from someone without the original engineering experience?
Types Spindles Rebuilt
- Grease Pack- Standard lubrication
for 7,500 - 10,000 rpm
- Air/Oil - Used for both 10,000 and
15,000 rpm spindles. Oil is atomized with pressurized air and
injected into the bearings. This provides maximum lubrication
efficiency while reducing internal heat. Although this
system is the most effective, conversion from Grease Pack to
Air/Oil is complicated and expensive.
- Mist Lube - Original lubrication on
earlier 10,000 and 15,000 spindles. Same basic lubrication
as Air/Oil but lacked monitoring systems.
About Air/Oil and Mist Lube
We are the only company to specialize in the "Air/Oil and Mist
Lube" spindles.
Customers with this type of spindle should not allow themselves to
be persuaded into switching over to a Grease Pack spindle,
but should maintain their existing Air/Oil or Mist Systems. In the
Machine Tool Environment the Air/Oil and original Mist type
lubrication systems are much better than the grease lubricated
spindles for several simple reasons:
- "Air/Oil and original Mist" lubrication systems keep the
spindle cartridge positively charged with an air/oil mixture
which helps to prevent the machine tool coolants from
penetrating the spindle cartridge.
- Both systems also provide a constant cleaning action to the
spindle bearings and races.
- In addition, they also cool the ball bearings and races and
help evacuate that heat from the spindle. Any heat in the
spindle reduces its life. The cooler your spindle runs, the
longer its going to last. Also, cooler spindle temperature
provide for a more constant temperature range which directly
translates to better depth control at the tool.
Not All Rebuilds Are The Same:
Over time and usage, the spindle taper tends to open up, this is
known as "bell-mouthing" the taper. While some companies just
regrind the taper without considering the spindle geometry, we
carefully inspect the taper to ensure if correcting the taper will
require too much material to be removed. If this is the case
we will Chrome plate the taper first then regrind the taper.
Doing this costs more but it guarantees that all spindles we ship
have the correct wall thickness between the spindle taper and the
spindle inter-bearing races (shown as Regrind Weakness in the above
picture). Too much taper grinding weakens the spindle shaft.
Beware -
We've even seen some spindle repairs just polish the taper with
sand
paper. While it might seem cheaper and it might look good, but
is it?
A quality spindle rebuild is more than replacing the bearings,
proper tool support is the key to all machining. The three
conditions most important in controlling taper are: taper size,
angle and straightness.
If the toolholder’s rate of taper is too great there will be
excessive clearance between the tool holder and the spindle at the
small end of the taper.
If the rate of taper is too small, there will be excessive clearance
at the large end.
An error in straightness is known as a "barrel-shaped" error and is
typically caused by bad tooling or hand polishing. Either
situation can reduce the rigidity of the connection and cause tool
run-out and chatter, which may show up on the work piece as geometry
and/or surface finish error.
Core Deposit Policy:
If we sold spindles without receiving a core return, we would
need to sell the spindle for over $4500 and eventually only new
spindles could be sold. In order to provide the best quality
and lowest cost spindle exchange, we offer a core credit for the
return of your spindle. It is our desire that you clearly
understand how core returns are processed (as fairly as possible).
Basically, the value of core return is based upon us receiving a
usable spindle i.e. a spindle that is repairable. You
will receive a refund check for $1000 if we receive a spindle that
simply needs cleaning, inspection, simple repairs, new bearings and
a minor grind on the taper.. Which is the case most of the time,
however when we do receive a damaged spindle core that needs repair,
the extra repair charges are deducted from the deposit. The $1000
deposit then is reduce by our cost to repair/replace the damaged or
missing parts. We will not deduct for minor repairs only for major
damage. For example, below are most of the worst case core
repair adjustments:
- Broken or Missing Drawbar: May reduce the
refund by $500.
- Spindle Taper damage: If grinding the taper
requires too much material to be removed, we must Chrome plate
the taper first then regrind the taper. Doing this costs
$500 but guarantees that all spindles we ship have the correct
wall thickness between the spindle taper and the spindle
inter-bearing races, see above.
- Damaged Key Way: When the key ways are
broken or severely damaged from crashes, we are required to
repair or replace the spindle shaft. The cost
depends on the severity of the damage. The worst case is
to replace the entire spindle shaft for $690.
- Bearing Seize: The spindle shaft bearing
journal can be damaged when a bearing seizes. The worst case is
to replace the entire spindle shaft for $690.
The total deduction will not exceed the core deposit. If
requested, we will return the spindle core to you (unassembled).
It is our goal that you understand our core return policy and that
we strive to come up with a core exchange program that is as fair as
possible.
Your satisfaction is important to us and we will gladly explain any
core refund reductions.
SPINDLE REBUILD REQUEST
FOR QUOTATION FORM:
