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  1. #1
    Join Date
    Jul 2011
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    Melbourne Australia
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    Default Spindle Weld Repair.

    Gentlemen.

    Thought I'd share a job that's been through my shop this week.

    I was sent this Spindle Cartridge assembly from Perth. It's had a bit of history. Its a #40 taper.

    They had snapped the bolts that hold the drive keys in. Must be a boomtown thing. Just Mig weld a new set in. While its assembled and sitting on the bearings.

    P1010273.JPG

    P1010274.jpg

    I don't know whats gone on to the face of that spindle. I suspect they tried to peen some meat into the key slot.
    P1010275.JPG

    I spent half a day last weekend getting the broken bolts out.
    P1010276.jpg

    Precision Spieth Nut disassembly. This is how it was sent to me.
    P1010277.jpg

    Phil.

  2. #2
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    Jul 2011
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    Melbourne Australia
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    Default

    Here's what it looks like today.

    P1010299.JPG

    P1010303.JPG

    P1010300.JPG

    P1010301.JPG

    P1010302.JPG

    I prepped it, and sent it out to a specialist welder. http://www.harvesteng.com.au/

    I still have a 1993 drawing of this assembly. I could tell them the spindle was made out of Bohler E200. They were able to match Tig weld, built up the keys, face and about 12mm deep to take the bell mouth out of the taper. Their deposit should be about 45RC.

    Reground Face, and taper. And I had the keys re-cut using CNC Wire EDM. Picked it up this morning.

    Getting my capabilities and ambitions missed up again. I've told them then can have it back on Wednesday.

    Regards Phil.

  3. #3
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
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    68
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    4,780

    Default

    Looks like a brand new unit, nice work Phil. Surprising what a bit of weld and machining can do.
    Kryn

  4. #4
    Join Date
    Nov 2006
    Location
    Heidelberg, Victoria
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    76
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    2,074

    Default Nice job

    Well done Phil, instead of gardening and dress making, you should get into the machine refurbishing business.

    Ken

  5. #5
    Join Date
    Dec 2011
    Location
    Sydney
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    Default

    Quote Originally Posted by Machtool View Post
    ... Just Mig weld a new set in. While its assembled and sitting on the bearings.
    Hi Phil,

    Impressive repair!
    Did the bearings need replacement as well?

    Bill

  6. #6
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
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    4,443

    Default

    Hello Phil,

    Most impressive Compared to how it was when it came to you, it now looks like new.
    I would have taken one look at it and said "bin job"...
    Best Regards:
    Baron J.

  7. #7
    Join Date
    Sep 2008
    Location
    Riddells Creek, Vic.
    Posts
    620

    Default

    Nice repair Phil, is the spindle from a Zenford Zeigler v.m.c?

  8. #8
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    Jul 2011
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    Melbourne Australia
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    Default

    Quote Originally Posted by WCD View Post
    Did the bearings need replacement as well?
    G'day Bill.

    P1010272.jpg

    I'm hoping this will buff out.

    They thought they might have a crack at this them selves. I got it sent over in a thousand bits. The farmers son in me says its all right to take to a bearing with a mig welder to get it out. On a bull dozer, but never inside a precision housing.

    I've had weld splatter in the bores. I've had to line lap them to get them back.

    Pictures of the inner and outer rings of one of the 4 angular contact bearings.

    P1010305.JPGP1010304.JPG

    Quote Originally Posted by Techo1 View Post
    Nice repair Phil, is the spindle from a Zenford Zeigler v.m.c?
    Its out of an Aussie - Melb built flame / plasma cutter. On certain models they throw this spindle, and an 8 tool carousel for drilling a few holes etc.

    They have through the spindle coolant. Most of these machines are in plate processors. No matter how many times you tell them, that that coupling needs regular inspection for leaks, they never bother. They drag straight water, loaded with iron oxide up out of the wet tank. Once the coupling leaks, its spills water all over the top of the spindle.

    Heres the top end of the drawbar and the coupling. Top of that coupling rattles about 8mm. Its been leaking for years.

    P1010310.JPGP1010311.JPGP1010309.JPG

    I have to replace all those components, plus a few others, place the ones they lost.

    I did this spindle up about 8 years ago, on that occasion I gave it the works, had all the parts Electroless Nickel plated at that place around the corner from me in Thomastown. Drilled the housing top to bottom, added an air port for air purge at both ends.

    I even put my version of an airshield in it. http://www.setco.com/airshield/

    P1010307.JPGP1010308.JPGP1010306.JPG

    I rework the old labyrinth seals out, and have the nose caps ceramic flame sprayed, diamond ground and lapped and run a Vee face seal against it, with the airpurge under the seal.

    I still have plenty of these running in the field with more than 10 years on them, as long as that coupling doesn't leak. I don't design them to run submerged.

    Regards. Phil.

  9. #9
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    Aug 2008
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    Default

    Quote Originally Posted by Machtool View Post


    Its out of an Aussie - Melb built flame / plasma cutter.
    Ahh that explains it... They are blacksmiths....
    Gold, the colour of choice for the discerning person.

  10. #10
    Join Date
    Jul 2006
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    Athelstone, SA 5076
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    Default

    Come on ...tell us you went out and bought a new one

    as WCD says,... very impressive repair Phil...

  11. #11
    Join Date
    Oct 2007
    Location
    Sydney
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    3,112

    Default

    Nicely done Phil, a very professional end result, as always.

    What did you grind the spindle face on? It looks like it may have been side wheeled, but if so I sure would like to see some shots of the setup if you took any?

    So you had the keys EDMed but cut the slots conventionally? The slots look like the may have been EDMed too. I've been both hard turning and boring hardened steels (no way of knowing the exact) harness in the past couple of weeks and it went much more smoothly than I would have thought likely. It's whet my appetite to work more up this end of the RC scale so if you have any more pictures of the actual process you went through you would be willing to share that would be terrific.

  12. #12
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    Aug 2011
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    Melbourne
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    Default

    Thanks for posting Phil. It's very interesting. I'm interested to know why the key ways look a "golden" colour. Is that the metal left from the mig weld?

    Simon
    Girl, I don't wanna know about your mild-mannered alter ego or anything like that." I mean, you tell me you're, uh, super-mega-ultra-lightning babe? That's all right with me. I'm good. I'm good.

  13. #13
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    Jun 2008
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    Victoria, Australia
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    Default

    Pretty slick bit of repair work very impressive.

  14. #14
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    Quote Originally Posted by Pete F View Post
    So you had the keys EDMed but cut the slots conventionally? The slots look like the may have been EDMed too.
    I've still got to make new keys. It was the slots in the spindle I had EDM wire cut. After the spindle was ground. I supplied a couple of M6 shoulder bolts, so they could pick up the screw holes, but the slots 15.9mm wide were centred off the ground OD.

    The keys bolt in, M6

    That yellowy colour is typical of an EDM finish. Wipe with a stone or diamond file gets back to base material.

    Regards Phil.

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