Troubleshooting
Please find below some typical spindle issues and the associated solutions:
Problem: Unable to reach maximum rated speed Verify VFD parameter settings.
Solution: Verify input line voltage to machine
Problem: Spindle vibration or rough edge cut on work-piece
Solution: Balance tool holders. Balance cutter. Dull cutter. Tool length exceeds maximum allowed.
Problem: Inadequate bearing life. Spindle noise or premature failure Overheating. Excessive feed rates. Unbalanced tooling.
Solution: Check warm-up procedure. Check feed rate. Check ramp-in angle.
Problem: Spindle overheating
Solution: Verify condition and operation of spindle cooling system (e.g., compressed air supply set properly, electric fan operating, shaft fan operating, chiller operating). Check incoming voltage. Check VFD for proper settings to match spindle.
Problem: Cutter stalls in cut
Solution: Reduce depth of cut. Dull cutters.
Problem: Tool holder sticking in spindle taper
Solution: Verify that the actuator is functioning. Verify adequate air pressure to the actuator. Check tool ejection (2.67-3.05 mm ISO & 0.5 mm HSK). Check that the cone cleaning feature (if applicable) is operating. Check cleanliness of spindle taper and tool holders. Check for proper pull stud. Note: Always remove tool holders from spindle before shutting the machine down.
Problem: Tool holders loose
Solution: Check taper (visual) for fretting. HSK requires regular cleaning to maintain proper clamping force. Check for worn tool holders. Check for worn taper. Check for proper pull stud.
Problem: Popping sound during tool change
Solution: Check for contamination in air line.
Problem: One of the most common failures is due to actuation while rotating
Solution: Check all adjustments and signals of sensors. "Use of sensors required for valid guarantee"
Problem: Cutter dropping out
Solution: Check threads for damage or wear, possible over tightening of collet nuts.
Problem: Cutters breaking frequently
Solution: Check cutter length. Possible feed rate too high. Removing too much material in one pass.
