Mazak Integrex Milling Spindle Repair

We warranty our Mazak Integrex Spindle repairs for 1 year. This blog shows some of the work that is involved with repairing a Mazak Integrex spindle to original factory condition and why we have confidence in our repairs.

Mazak Integrex components laid out for pre-assembly inspection.

In one of our previous blogs we spoke about some of the damage that we find on the Mazak Integrex spindles that are sent to us. This blog will show a little more detail of some of the components that go into the Integrex milling spindle and efforts we make to insure an OEM equivalent repair.

These arrayed detents allow the Integrex Spindle to be locked in a wide variety of positions.

The Integrex Milling spindle raises the level of complexity of spindle repair. This spindle is the key to the Mazak Integrex versatility. So when you need one repaired you want to go to a spindle repair facility that has extensive experience and a proven track record. It is not a spindle you want repaired by beginners. At HST we repair Mazak Integrex spindles to like new condition and we back them up with an OEM equivalent warranty. With 26 years under our belt we are one of the oldest independent spindle repair shops.

HST will clean all orfices and replace all seals for the hydraulic actuator.

After forensic examination as to the cause of failure, all components are thoroughly cleaned and then laid out for pre-assembly inspection.

The spindle allows the Integrex machines to perform super precision high speed milling. The arrayed detents are hydraulically actuated to lock the spindle in a particular position. When the spindle is locked in position it becomes a versatile tool post that can work in conjunction with the two lathe spindles. These arrayed detents must be carefully aligned when installed.

Assembling a drawbar with new springs.

When we repair an Integrex the hydraulic actuator and associated components are completely rebuilt. Dimensions, surface conditions and all orifices are carefully checked. All seals and wear components are replaced.

Preparing to remove the hydraulic rotor from an Integrex Shaft.

Drawbar springs can develop hairline fractures from fatigue. At HST we don’t take any chances; all drawbar springs are replaced. The Integrex employs two sets of double wound springs. These are more expensive than the common Belleville style. The drawbar springs are carefully lubricated and all seals are replaced.

Along with drawbar sub-assembly the gripper assembly is carefully inspected and recommendations are made to the customer whether to replace or reuse the grippers.

Special adaptors are required to remove the hydraulic rotor. The rotor must be removed to access the front bearings. Hydraulic rotors and hydraulic nuts are removed by installing special adaptors and pressurizing the interior. The hydraulic pressure causes the rotor to expand until it “pops” off of shaft.

Prior to removal all components are carefully “marriage marked”. This is required to insure that all components are re-assembled back to the original positions. This helps to minimize trim balancing and speeds up the break-in process.

Once removed the surfaces must be carefully inspected for any scratches or damage. The orange stripe on the edge of the rotor is balancing putty installed at the factory. By maintaining the original alignment of all rotating components we may not need additional corrections for mass distribution imbalance.

The Integrex spindle has a magnetic rotor so additional care is required when reassembling the components.

Here we see a few of the orifices that transmit hydraulic fluid to different actuators.

The front set of bearings are mounted back to back and held with a precision threaded nut. The factory uses Koyo pre-lubricated sealed bearings and an NTN roller in the back. After these are properly installed and loaded. The hydraulic stator can be reinstalled.

To actuate the locking mechanism, drawbar actuator, cool the bearings and provide tool coolant the spindle components have dozens of orifices and passages drilled in them. Some are straight through; some are cross drilled, some are drilled at an angle and some are rather minute. At HST we carefully clean and inspect each one. It is critical that all components are properly lined up and that every o-ring is the right size and properly seated.

The Integrex machine transfers fluid into the milling spindle through a rotary union and by flexible lines. Tool coolant goes through the rotary coupling. At HST we will replace all tubing connectors as required. However, the flexible tubing is the responsibility of the installation technician. The rotary coupling is thoroughly examined and rebuild as required.

The rotating union is a minor rebuild project by itself. It has its own set of o-rings, back up rings, bearing and retaining clips. These components are replaced during a comprehensive rebuild.

The Integrex is a complicated spindle that requires dozens of o-rings, properly sized and seated to perform flawlessly.

The spindle also has a high speed rotating union that mounts to the shaft. This employs a highly polished ceramic disc. Special care must be taken to protect this disc from scratches, chipping or other damage.

The Integrex milling spindle uses a rotary encoder for closed loop speed feedback and positioning for tool changes. The gap and position of the rotary encoder is critical for proper operation.

It’s not very big. But the ceramic disc is critical for proper operation.

The rotor and shaft are installed into the front bearing housing and become a separate sub-assembly. Once that group passes some tests it is carefully installed into the main housing. After the rotor is installed the stator is double checked for electrical integrity. After that check the rear roller bearing is installed along with some other back end components. Note, the back cover, drawbar actuator sub-assembly, and through tool coolant assembly are not installed at this time.

Removing the rotary coupling during spindle dismantling. Note residual tool coolant.

The spindle is run-up on our test bench to check for balance and vibration. The back cover is left off to allow for any corrective trim balancing that might be needed.

To ensure that all o-rings are seated and aligned properly HST has fabricated adaptors for the various styles Integrex spindles. By pressure testing the whole spindle for 24 hours we are confident of the spindles liquid tight integrity.

All of the wiring connections are double checked. Besides the stator, the internal thermistors are checked and proper operation rotary encoder is verified.

This Integrex Spindle is mounted on our run-up bench almost ready for testing. Note the back cover is left off for trim balancing.

Once the spindle passes all of our exhaustive testing it heads to the paint booth. After all appropriate surfaces are “taped-off” a two part, high solids epoxy paint restores the spindle so it not only performs like new; it looks like new.

The Mazak Integrex series of machines offer incredible versatility and capability. But should your spindle have a problem, we do not recommend attempting to repair it by yourself.

These are very complex spindles and require a highly technical repair. High Speed Technology has the technology, equipment and experience to rebuild your spindle to like new condition, and we stand behind our repairs with a one year warranty.

Our turnaround time is short and our pricing is very competitive. So if you have a problem give us a call; we’ll answer the phone.

For more information about spindle repair please visit our FAQ or Portfolio section for information on specific questions or brands.

An Integrex spindle, repaired, painted
and ready to ship.

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