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LAST UPDATED: 02/14/2020
Spindle - Mill - Troubleshooting Guide
Spindle - Mill - Troubleshooting Guide
Page 1 of 11 pages
Introduction
Spindle - Mill - Troubleshooting Guide
Page 2 of 11 pages
EXPLODED VIEW:
1. ENCODER NON-CONTACT KIT 3" I.D.2. SHCS 8-32 X 1/2 LOCTITE PATCH3. READ HEAD MOUNTING PLATE4. FBHCS 1/4-20 X 3/4 W/LOCTITE PTCH5. SHCS 1/4-20 X 1 3/46. SPINDLE ENCODER MOUNT7. SHCS 10-32 X 1 1/48. ENCODER RING ADAPTOR9. SHCS 5/16-18 X 1 1/4
10. O-RING 2-216 BUNA SHORE A 9011. SPINDLE TOP CAP12. DRIVE SPROCKET13. BHCS 1/4-20 X 1/2 ZINC PLATED14. FITG NPT1/8M PLUG STL15. SPINDLE INJECTION COVER 50T MPO
DUAL PORT NCE16. O-RING 2-349 BUNA SHORE A 5017. DRAWBAR ASSEMBLY18. SPINDLE LOCK UPPER19. UPPER BEARING20. SPINDLE BEARING LOCK21. O-RING 2-160 BUNA22. OUTER SPACER23. INNER SPACER24. LOWER BEARING25. INJECTOR ASSEMBLY26. SPINDLE SHAFT27. O-RING 2-368 BUNA28. SPINDLE HOUSING29. O-RING 2-353 BUNA30. SHIM FRONT CAP31. SPINDLE CAP32. SHCS 3/8-16 X 1 LOCTITE33. O-RING 2-109 BUNA34. O-RING 2-111 BUNA35. WASHER #8 FLAT SAE .375 OD36. WASHER 0.260 FLAT
Spindle - Mill - Troubleshooting Guide
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Mill 40-Taper Belt-driven Spindle with TRP
1. TRP2. Spindle belt pulley3. Upper bearing4. Drawbar5. Spindle cartridge6. Head casting7. Spindle shaft8. Lower bearings9. Toolholder
Spindle - Mill - Troubleshooting Guide
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Symptom Table
Spindle - Mill - Troubleshooting Guide
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Symptom Possible Cause Corrective Action
The spindle lubrication systemis not functioning correctly. Inspect the spindle lubrication system.
The spindle has been crashedand now damage.
Review alarm history for indications of a crash, check for visualdamage to the spindle.
There is heavy side loadscausing the cap to gall theshaft.
Check for clearance all the way around with a piece of 0.001”shimstock; loosen the cap, re-center and tighten.
The Spindleis seized or itwon't turn.
The precharge solenoid getsstuck during a tool change.
Inspect the precharge solenoid. For CALM machines inspect solenoidmanifold inside the lube panel for contamination. Check insidethe water separator housing for a broken filter.
The spindleis hot.
The spindle lubrication systemdoes not function correctly. Check for a clog in the spindle lube pump and verify the type of oil.
The spindle lubrication systemdoes not function correctly. Check for a clog in the spindle lube pump and verify the type of oil.
The spindle drive belt is wornor damaged. Check the spindle drive belt for damaged.
The spindlemakes anunusualnoise.
The encoder pulleys or drivebelt are worn or damaged. Check the encoder pulleys and belt.
The spindle drive belt is wornor damaged. Check the spindle drive belt.
The encoder pulleys or drivebelt are worn or damaged. Check the encoder pulleys and belt.
The drawbar force is incorrect. Make sure the drawbar clamp force is correct. Refer to: VMC - Spindle -Drawbar - Force Measurement
The fixture does not supportthe part. Adjust the cutting load or program.
The spindle is not balanced. Contact your HFO to balance the spindle.
The toolholder is fretting. Verify the length of the tool with the manufacturer's specifications.
The spindle bearings aredamaged. Perform a vibration analyzer.
Excessive Endmill Runout -Mill.
Tool runout should not exceed 0.0003" (0.076 mm). To check the toolrunout, place a dial indicator on the tool, and then rotate the spindleby hand.
The surfacefinish showschatter, orthe spindlevibrates.Alarm 966EXCESSIVEPART/TOOLIMBALANCE.
The tool is unbalance. Balance the tool holder with the cutting tool in it. If you cannot balancethe tool assembly, replace it with one that you can balance.
Spindle - Mill - Troubleshooting Guide
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The tool or tool holder may betoo long for the application.
Longer tools are less stable than shorter tools. Always use the shortesttool possible, and remember that a 10% reduction in the length-to-diameter ratio results in a 25% increase in tool stiffness. Unlessabsolutely necessary, the tool's stick-out from the holder should notbe more than 3 times longer than its diameter.
The drawbar force is incorrect. Make sure the drawbar clamp force is correct.
(Through-spindle coolantonly) Some coolants causetools to stick.
Coolants containing paraffin waxes can causing sticking tools whenusing high pressure Through Spindle Coolant with small orifice tooling.Test with a different type of coolant.
The volume of air supplied tothe machine is not sufficient.
Refer to: New Machine / Pre-Installation information for the correct airrequirements.
The tool stayed in the spindlefor hours while the machinewas not in operation.
Make sure a tool is not in the spindle when the machine is not inoperation.
There is no grease on the pullstud. Lubricate the pull stud.
The toolholder is fretting.Damage tool shank or spindletaper.
Verify the length of the tool with the manufacturer's specifications.Maintain and inspect tool holders, and spindle taper.
The spindle is getting too hot. Test the spindle lubrication system. Lack of, or excessive oil will createheat in the spindle.
Tools stick ordo not comeout of thespindleeasily.
Long gage length tooling. Stub up the tools to the extent possible. Reduce depth of cut. Usedynamic tool path and constant cutter engagement.
Angular contact bearings thatare mounted incorrectly canbe noisy.
Too little preload can causethe balls to skid and the cagesto chatter.
Too much clamping load candistort the races and cause theballs to skid, in turn creatingcage chatter.
Bearings seated out of square.
Increasing the thickness of the shim under the front cap can eliminatethese noises.
Squealing noises from the TSCunion. Check the TSC union.
Whilerunningthere isbearingNoise:squealing,screeching orskating.
Noise from imbalance andvibration Make sure the tools are balanced.
Rubbingnoises; Heatat the frontcap.
Spindle cartridge has beenbumped there is a chance thefront cap has been pushed toone side and is rubbing on thenose of the spindle shaft.
Check for clearance all the way around with a piece of 0.001”shimstock; loosen the cap, re-center and tighten.
Spindle - Mill - Troubleshooting Guide
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Noisesduring toolchange.
Some models have had theprecharge circuit eliminated.
This is a reliability improvement but a noise can be heard when theTRP contacts the drawbar or the release ring. This is normal.
A NGC software error inversion 100.17.000.xxx thatcaused a noticeable growlingnoise during rigid tapping,particularly with coarse pitchthreads.
Update software to the latest version.
Noise duringrigid tapping.
Problems with the spindleencoder can also causeproblems.
Look for runout, loose mounting screws or shaft clamps, and any otherobvious problems.
The Wye contactor (ifequipped) coil is not receivingpower.
Make sure the Wye/Delta contactors are operating correctly. Referto: Wye-Delta Contactor - Troubleshooting Guide.
The spindle motor wiring isincorrect.
The spindle motor wiring is incorrect. Refer to: Spindle Motor - WiringConfigurations.
The spindleoscillatesduringspindleorientation.
The vector drive is defective. The vector drive is defective. Refer to: Vector Drive - TroubleshootingGuide.
Lubrication
Corrective Action:
Insufficient or excessive oil supply to the spindlebearings can cause the spindle to overheat. Usingthe incorrect spindle lubrication oil on the spindlebearings can cause the spindle to overheat. Makesure you use the correct spindle lubrication (SHC625) and the air pressure to the spindle is correct.
Inspect all tubing, hoses and fittings in thelubrication system for leaks. Check for puddles ofoil to help locate leaks.
Go to HAAS SPINDLE MINIMUM LUBRICATIONTROUBLESHOOTING for additionaltroubleshooting information
Go to MECHANICAL BIJUR LUBE PUMP -TROUBLESHOOTING GUIDE for additionaltroubleshooting information.
Spindle - Mill - Troubleshooting Guide
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Drive Belt
Encoder Pulley/BeltCorrective Action:
Make sure the encoder belt is adjusted correctly and is not damaged. Replace a damaged or worn belt.
Make sure the encoder pulley is not worn. Make sure the set screw is tight.
Drawbar Force
CoolantCorrective Action:
If the machine has through-spindle coolant (TSC), different types of coolant can cause the toolholder to stick in thespindle. Consider a different type of coolant if the symptom persists.
Corrective Action:
Power off, lock and tag out machine. Remove thespindle head covers. Disconnect the air supply tothe machine. Remove the four 3/8-16 SHCS onthe TRP. Remove the TRP and set it aside.
Inspect the spindle drive belts and pulleys fordamage: Look for frayed, stretched or brokenbelts, and damaged or stripped cogs on theinside surface of the belt. Refer to the DRIVE BELT- TROUBLESHOOTING GUIDE.
Corrective Action:
Use a drawbar force gauge in the spindle tomeasure the clamp force. Refer to SPINDLE -DRAWBAR FORCE REFERENCE TABLE.
If the drawbar force is incorrect, go to SPINDLE -DRAWBAR - TROUBLESHOOTING GUIDE.
Spindle - Mill - Troubleshooting Guide
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Workholding
BalanceCorrective Action:
Make sure the spindle is balanced. Your local HFO can balance these spindles:
• All belt-driven spindles• Inline spindles made after August, 2016
All tooling that runs over 10K RPM must be balanced. Do not exceed the manufacturer recommendations for specialtooling.
Toolholder Is Sticking
If the workholding does not adequately supportthe part, it can cause chatter.
Corrective Action:
Stiffen the workholding if possible.
Lower the cutting load with adjustments to thetool selection, or the program.
This effect can occur while the machine is inoperation if a cold toolholder is placed into awarm spindle taper. This creates thermalexpansion [1] on the sides of the toolholder andmakes it stick in the spindle taper before it isreleased.
A common example is if you change from a hotcutter to the cool spindle probe to check yourpart at the end of a cycle. If the cool probe is leftin the hot spindle overnight, it will make a"popping" noise when it is released.
Corrective Action:
Clean the toolholders and spindle taper. Checkfor damaged toolholders before you put themback in the machine. A damaged toolholder cancause damage to the spindle taper and createtool runout or problems with finish.
Make sure the pull stud is lubricated. Refer tothe MILL - TOOLING - MAINTENANCE procedure.
Spindle - Mill - Troubleshooting Guide
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Toolholder Is Fretting
BearingsCorrective Action:
Damaged bearings in the spindle can cause finish issues on the part. Contact your local HFO for a vibration analysisto see if the bearings are damaged.
Corrective Action:
Look for fretting on the toolholders. Long toolscan cause fretting on toolholders if you use themaggressively. If there is fretting on the toolholder,or if the symptom persists, go to SPINDLE -DRAWBAR - TROUBLESHOOTING GUIDE.
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