Machinery Rebuilders

About Machinery Rebuilders and Machinery Rebuilding Including: Machine Tool Repair, Machinery Repair, Press Rebuilders, Spindle Rebuilders & Tool Rebuilders.

Machinery rebuilders are service providers that disassemble, clean and fix machines. Machinery rebuilding generally refers to the simple disassembly and diagnosis of machine conditions. All parts of a machine, such as upper and lower press and drive components, cushions, linkage, shafting, gearing, press attachments and slides, are inspected, cleaned and replaced if necessary. After proper inspection and any necessary improvements are performed, the machine is then reassembled. Often, older machines will be fitted with features that were not available when they were first purchased. Machinery rebuilders are ideal for machines that are basically sound but have some problematic deficiency that keeps them from being profitable.

Three main types of machinery rebuilding are retrofitting, remanufacturing and rebuilding. Typically, retrofitting refers to an upgrade of CNC machines only. A complete retrofitting procedure includes upgrading and replacing many machine components. Retrofitting provides significant cost savings, a shorter delivery time than a new machine and requires no new training for maintenance personnel. Remanufacturing is the most extensive restoration service and includes processes performed in both rebuilding and retrofitting. In the remanufacturing process, the machine is dismantled, cleaned and degreased. Then, the parts are inspected and replaced if they are worn or damaged. All of the bearings are ground, scraped or replaced, along with worn shafts and bushings. The components and then the machine are reassembled and the machine is demonstrated and usually painted prior to shipping.

Maintaining machinery through rebuilding offers numerous benefits like better product output and overall profitability. Many work hours and constant stopping/starting cycles put generous amounts of normal wear and tear on machines. Simple repairing, rebuilding, retrofitting and remanufacturing can increase the productivity of an older machine. Another benefit of rebuilding an existing device is that the controls and functions remain familiar to the corporation or business. Buying a new machine means higher costs and numerous commands and utilities to learn. With proper knowledge and precise rebuilding, the capability of an old machine may surpass that of a brand new unit, while keeping costs to a minimum.

Many industries benefit from machinery rebuilding services, including the forging, forming, stamping, die casting, steel processing/making, injection molding and metals industries. Most machine rebuilder customers are mid- to large-sized companies that can endure production loss while the machine is being restored. Typically, the remanufacturing of big or complex machines takes about 20-24 weeks, while a rebuild takes about 14-16 weeks. The retrofitting process usually takes from one to 10 weeks. Machines should be restored by machinery rebuilders only if the cost of rebuilding is less than 60% of the cost of a new machine. Rebuilding, retrofitting and other machinery restoration is usually reserved for larger machines, such as boring mills, large-chuck lathes and big-table horizontals, as repairing smaller machines like VMCs or HMCs can easily exceed the 60% tenet.

Types of Machinery Rebuilders

• Machinery repair refers to any service or process performed on a machine which results in a fixed or upgraded working status. Machinery repairs include rebuilding, retrofitting and remanufacturing and can cost anywhere from 10 to over 50 percent of the price of a new machine.
  
• Machine tool repair generally calls for all of the components of a machine to be cleaned, inspected and then reassembled using refashioned or new parts. Machine tool rebuilding usually costs around one-third the fee of a brand new unit.
  
• Press rebuilders refit presses with press controls, gears, shafts, clutch retrofits, etc. Press rebuilders service a variety of presses, ranging from small C-Frame presses to large straightside presses, typically automating and restoring them to a better-than-original status.
  
• Remanufacturing includes a retrofit upgrade, as well as a rebuilding service, which can cost up to 50 percent of the price of a new machine. In conjunction with these improvements, remanufacturing may also include design changes to benefit the performance capability of a machine beyond its original standards.
  
• Retrofitting generally refers to the upgrading or replacing of a CNC machine's servomotors, magnets, drives and wiring components. The cost of retrofitting ranges from 10 to 30 percent of the cost of a new unit.
  
• Spindle rebuilding includes the complete disassembly and inspection of a spindle assembly and a possible balancing phase to correct the center of gravity. Internal bearings are taken out and substituted with new ones, the spindle gears are inspected for cracks/wear and the shafts are checked for straightness.
  
• Tool rebuilders refit tools with press controls, gears, clutch retrofits and more. Service a number of tools within a machine and can typically restore they to a better-than-original status.

Machinery Rebuilders Terms

Average Life - The average length of time a component will last before it fails.

Bearing - A piece which guides, supports and reduces friction between both fixed and moving machine parts.

Buffing - Shining and smoothing of a surface using an abrasive material. Buffing compounds are commonly embedded in a belt or soft wheel.

Computer Numerical Control (CNC) Machine - A microprocessor controller dedicated to a machining tool. A CNC machine has programmable numerical controls to activate its spindle drive and servos, controlling various operations.

Counterbalancing - The use of weights to balance a work piece or rotating device, reducing machine vibrations while maximizing cutting force. Spindle rebuilding often involves this method.

Debugging - The act of performing adjustments to a new or contaminated system in order to ensure proper operation and maximized production.

Demanufacturing - A disassembly process that is used for products that will be recycled, such as vehicles, in order to reuse their materials.

Durability - The capability of products to be utilized for a longer period of time than other comparable products with minimal degradation.

Finishing - Any of various processes used to provide edges, surfaces and corners with desired properties. Common finishing practices include preparation, conditioning, cleaning and coating.

Grinding - A machining procedure in which excess material is removed from a work piece by way of a powered abrasive stone, wheel, belt, sheet, paste, compound, etc.

Inspection - The act of physically checking a machine or product for assurance that it meets specified dimensions or performance levels.

Interchangeable Parts - Components that are built to specific tolerances. The similarity allows them to be mass produced and substituted for one another.

Lapping - A finishing operation using a fine-grained abrasive mixed in with a liquid to correct minor surface imperfections and produce a tight fit between mating surfaces.

Part Orientation - The layout of a feeding mechanism, machine and product so that the components are properly aligned prior to and during assembly operation.

Polishing - A process that uses abrasive material attached to a backing. Polishing blends contours and improves surface finish.

Recycling - The process in which materials that would otherwise be destroyed are collected, processed and remanufactured into new products.

Refurbishment - A process by which a product is brought up to a new standard through extensive work for use in a new application.

Retooling - The act of revising and/or reorganizing with a new and improved set of machinery tools.

Servo - A control system which converts a diminutive mechanical motion into one that requires much more power.

Spindle - A mechanical part, found on CNC machines, which revolves and serves as axes for other, larger rotating parts.

Truing - A process utilizing a dressing tool, such as a diamond, to ensure that a grinding wheel is concentric and round. Truing assures that there will be minimal vibrations.