Most Common Causes of Spindle Failure

There are several causes that can lead to the failure of a high-speed, high-performance spindle. However, the two most common causes of spindle failure that we have seen here at FISCHER USA are Vibration and Peripheral Support System Failure.

As a spindle manufacturer, we know that vibration is present in any milling process. However, spindles generally experience vibrations ranging from 0 mm/s to 10 mm/s. When the vibration levels increase above normal for an extended time, the vibrations can cause damage to the various components. The component that is most often damaged due to vibrations is the clamping system. Other components can also sustain vibration damage including the rotary union, bearings, shafts, bearing carriers, and more. Fretting, bearing failure, damage to power leads, and leakage due to wear of sealing surfaces are all signs of possible vibration issues. As these forms of damage can be caused by various spindle issues, often the root cause goes misdiagnosed.

The second main cause of spindle failure is when a peripheral support system has failed and/or is not properly maintained. This can lead to loss of lubrication, incorrect air supply setting, and hydraulic system contact during rotation. These issues may often go unnoticed by the system sensors, but can lead to heavy damage on spindle components which will need to be replaced.

If you are experiencing issues with your high-speed spindle or have noticed an increase in spindle failures, contact us today for a solution. We will perform a full and detailed inspection to determine the true root cause of the failure and provide you with a complete diagnostic report before repairing your spindle. Each repaired spindle is then fully tested as if it were on your machine, not just run-in.