Pre-mature failure of bearing in Machine Spindles is due to various reasons:

1. Unbalanced Tool Holder, collet, and tools
2. Entry of Dust Particles/Contamination
3. Wrong usage
4. Insufficient cooling
5. Insufficient Lubrication

 

      1 . Unbalanced Tool Holder, collets, and Cutting Tool

MachineSpindles are designed for 6,000 rpm to 60,000 rpm depending upon the application. If the tool holder, collet, and cutting tool are not balanced for Spindle rpm, it will generate excess force and cause premature bearing failure. The solution for this problem is to use a balanced Tool Holder, collets, and cutting Tools

 

2. Entry of dust particles/ contamination

If the machine does not have a proper chips/dust removal mechanism, it may enter the spindle and cause premature spindle bearing failure. The solution for this problem is to use vacuum dust collectors and avoid using pneumatic air for cleaning inside the machine. Also using air purging, one can avoid dust particles entering inside the spindle.

3. Wrong Usage

We observed so many customers using woodworking spindles for marble carving, and steel engraving. Then the spindle bearing fails because of excessive load.

 

Also, most of the woodworking spindles are not designed for handling wet cutting. If the water enters the spindle, it damages the collet, rotor shaft, and spindle bearings. Before using the spindle discuss with the supplier whether the spindle is designed to handle the wet cutting, and cutting loads

4. Insufficient Cooling and No rest for the Spindle

See the typical spindle bearing failure because of overheating

Air-cooled woodworking spindles require 1-hour rest after 8 hours of continuous running. But most of the customers are not aware of this and they use the spindle for more than 20 hours continuously. Then the Spindle becomes very hot and bearings fail prematurely. Solution: 1) Give rest to the air-cooled spindle after 8 hours continue running or keep the machine in an Air-conditioned room. 2) Switch to a water-cooled spindle and use a chiller for cooling the spindle.

5. Insufficient Lubrication:

Insufficient lubrication leads to excessive wear, overheating, and subsequent bearing failure. If the machine spindle is idle for two months. Bearing will not get proper lubrication. It is advised to rotate the spindle every 15 days so that the proper lubrication happens. Do not start the machining process directly when you are starting the machine in cold. Always run the spindle with a tool for 2 minutes in idle condition at maximum rpm. This will increase the bear’s life and the spindle’s life!

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