How to Recognize Early Warning Signs of Spindle Damage
There’s little argument regarding how important high-speed spindles are in CNC machines when it comes to machining precision parts. If your spindle suffers any damage or defect, the quality of your products and the output of your operations will suffer. In the short term, a damaged spindle may only result in faster tool wear and a little downtime. However, the longer the spindle is allowed to function without repair or replacement can lead to long-term consequences for your operations and your return on investment.
The good news is that there are plenty of early warning signs of potential spindle damage. These warning signs provide the heads-up that you must take appropriate action to repair or replace your spindle before it negatively impacts your products, operations, and revenue. Below are some of the major red flags for high-speed spindles to look for to help prevent further damage and ensure precisely machined products.
Wear and tear of precision tools isn’t uncommon. In fact, it’s expected over time as part of any high-speed machining (HSM) operation. However, abnormal wear and tear is far from common and a good indicator that you probably have an issue with a spindle that needs immediate action. If you haven’t changed your operational tempo, output, or source material yet, your tools are looking beat up and worn down; it’s time for an inspection, at the very least.
Spindle issues that can lead to increased and abnormal tool wear include:
- Worn or shot bearings
Inspecting and grooming equipment never hurts, even if your tools seem fine. Replacing tools is normal, but replacing tools on an above-average basis is a sign of a larger problem that needs addressing.
Deteriorating Product Precision and Accuracy
Faster-than-normal tool deterioration isn’t the only warning sign of a potential spindle issue. If you notice precision and accuracy problems with your final products, your spindle may be the single point of failure. Your quality control efforts may reveal product problems such as:
- Rough, irregular surfaces (chatter marks)
- Out-of-tolerance edges and other rough finishes
- Complete product quality failure
Now if you’re having any of these problems, especially the third item noted above, an inspection ensures your CNC machine receives the appropriate attention it needs. This will also ensure that no further money is wasted on products that ultimately fail a final quality inspection. Worn tools can be replaced, but poor-quality products cost you money and potential clients down the road.
There doesn’t always have to be noticeable damage present to notice a warning sign of potential spindle problems. In fact, noticing a potential problem before the spindle is damaged is always the preferred scenario.
One warning sign you may notice is overheating. In this scenario, you can prevent spindle damage before bigger problems occur.
Heat generation and hard work go together, and hard work is unavoidable for CNC machines. However, temperature monitoring should also be part of normal operations to ensure critical components like high-speed spindles don’t overheat and suffer failure. If your spindles are running hotter than they should, or you’re noticing unexpected and abnormal swings in temperature, take a look at your:
- Cooling system for proper operation and integrity
- Lubrication levels and system function
- Bearings for indications of unusual wear and degradation
Unusual Noise and Vibration
Sometimes the earliest indication of a problem with a high-speed spindle isn’t visual but audible. And it’s pretty easy to notice when something sounds “off” with any machine you’re used to hearing run at its optimal performance settings. Those “off” sounds can include:
- Grinding (not to include grinding operations)
In addition, it’s not uncommon to experience unusual equipment vibrations in conjunction with unusual equipment noise. Like with noise, you’ll usually recognize an unusual vibration compared to normal operating vibrations rather easily. Like unusual noises sound “off,” unusual vibrations will give the equipment an “off” feeling.
If you’re lucky, you may notice unusual vibrations early during a vibration analysis before you ever feel them. If so, you may pick up on the vibration issue before hearing an unusual noise or feeling your equipment shudder or pulse when it shouldn’t. In cases like this, you may be well ahead of getting the problem identified and fixed before any serious damage takes hold.
The cause of the noise and vibrations could be anything from bearing issues to misalignment or more. Then again, the problem may not be spindle related. It could be a completely different component of the machine, causing noise or vibration. As with the other warning signs above, the only way to know for sure is to conduct an inspection.
Not every CNC machine is equipped with electricity consumption monitoring capability. However, if you’re interested in tracking the energy your CNC machine consumes versus what it’s rated at, there are options. Energy use analysis is a good tool for monitoring equipment efficiency and helping detect potential problems with that equipment.
If you notice your machine consumes more power than it should, it could indicate a spindle problem or damage. Again, the problem may be with the bearings or alignment and could cause increased operating friction and increased power draw.
No one wants to deal with a high-speed spindle problem, especially when the spindles in your CNC machines are the heart of your operations. However, detecting and correcting potential spindle damage by recognizing early warning signs can be the difference between a quick repair and a complete operational shutdown. Recognizing the warning signs can save you money on equipment, prevent operational downtime, and preserve product quality.