This article contains everything you need to know about machine rebuilding and its importance to manufacturing
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Machine rebuilding is the process of reconstructing a machine by removing all its parts and repairing them or replacing them with OEM original components in order to bring a machine up to manufacturer specifications. It includes cleaning, repairing, rebuilding, and minutely monitoring every aspect of a machine as its parts are re-machined or replaced with new parts. Machine rebuilders go to extraordinary measures to ensure that a rebuilt machine meets its original specifications and standards such that it operates as though it were brand new.
Every manufacturing operation has a set of reliable machines that are the center of their processing and the production of their products. Companies depend on their machines to produce parts and components that are necessary for the operation of an application or the assembly of a product. As with any mechanical device, machines degrade and wear out over time with some becoming out of date and technologically behind the times. In those cases, it may seem logical to purchase new replacement equipment.
Machine rebuilding offers a cost-effective alternative to replacing reliable dependable equipment with new equipment. Rebuilders provide technologically advanced solutions for maintaining and sustaining on hand equipment that has proven its value for many years. The complicated process of machine rebuilding examines every aspect of a machine’s function and brings it up to date.
The process of machine rebuilding moves far beyond the concept of machine repair where an immediate concern is quickly fixed. In the repair process, a technician evaluates the present performance of a machine to determine what component or element is inhibiting a machine’s proper performance. Once the diagnosis has discovered the issue, the issue is repaired, much like putting a bandaid on a cut.
Machine rebuilding is more complex and complicated than fixing an immediate problem. Like a doctor of whole medicine, machine rebuilding takes in every part of a machine, down to the most minute detail, and brings the total machine up to date to match modern technology. When a machine has been rebuilt, it has the appearance of a completely new piece of equipment ready for several more years of service.
Machine rebuilders inspect every aspect of the operation of a machine including its mechanical operation, hydraulics, lubrication, pneumatics, electrical, controllers, and coolant systems. In the rebuilding process, every machine system is disassembled, cleaned, inspected, tested, and repaired or replaced.
For a machine to be effectively rebuilt, it has to be disassembled into each of its individual components and parts, which have to be cleaned and inspected for damage and wear. The disassembly process entails breaking down the machine and determining the type of damage and wear it has from its work cycle. All parts are examined regardless of their size, importance, or location on the machine. Nothing is overlooked.
The cleaning process makes it possible to examine for deficiencies, defects, and wear of parts and prepare them for the painting phase of the process. An image of each part is scanned, saved, and categorized during disassembly. Scanning makes it possible to quickly and efficiently reassemble the machine during rebuilding. It further ensures that at the completion of the rebuild process, the machine will be reassembled according to the original manufacturer's design and specifications.
The guideways of a CNC machine are a part of the machine that determines how the tools of the machine move along the axes. They include a carriage attached to a rail to drive the cutting tool or table. Guideways are the most important part of a CNC machine. Disassembling them is an extremely critical part of the rebuilding process. How guideways are refinished is dependent on the design, configuration, and structure of the machine.
Cleaning of guideways is a manual process that necessitates hand scraping to ensure the surfaces of the guideway match and make even and smooth contact. The delicate process of hand scraping is a special skill that requires years of training and practice. The success of the process is indicated by the surface having the proper bearing area and final alignment. Bearing areas should have 10 to 15 contact points per square inch with the total contact being 50% to 60%.
Newer CNC machines have guideways that do not require being scraped and are coated with a low friction material such as SKC3, Moglice, or Turcite on one of the mating surfaces. The low friction coating can be replaced and the guideways way can be reground, finished, and aligned. Guideways that have a linear bearing pack on a hardened linear rail are replaced completely with a new guideway.
The lead screws move the machine’s slides and are acme screws and ball screws. Servo controlled machines have ball screws while older CNC machines have acme screws. The screws are removed during disassembly and repaired or replaced. When the screws are being replaced, new thrust bearings are installed to avoid axial lash in the drive mechanism.
Wear parts include bearings, bushings, seals, and wipers, which should all be replaced and not repaired. The only exception to this rule is parts that rarely move during the operation of the machine and should be in prime condition. This exception does not apply to rubber or felt parts such as seals or wipers that should be replaced, regardless. Lined parts such as clutches and brakes should be replaced as a matter of caution since they are difficult to inspect due to being sealed units.
Machines that produce gears use gears as part of their process. Gears are constantly in motion during the operation of a machine. Teeth, bores, and keyways can become worn because of the constant motion and stress. The most critical gears in a machine control worktable and cutter rotation. Wear in these gears will be evident in the gears the machine produces. Close inspection of gear spacing and tolerances of gears in the cutter spindle assembly and worktable are essential to the machine rebuilding process. When the machine is being reassembled, the lash in these gears has to be precision adjusted since excessive lash can damage the gears produced by the machine.
Every aspect of the reassembly has to have the alignment checked and verified. Parallelism and perpendicularity of the axes has to be maintained as the guideways are being refinished and during the power up of the machine. The International Organization for Standardization (ISO), the Deutsches Institut für Normung (DIN), and the American National Standards Institute (ANSI) have published allowable tolerances for these alignments. In addition, machine manufacturers have tolerance guidelines for their machines to serve as a guide during reassembly.
Of the many systems of a machine, the electrical system is the most critical since it controls the operation of the machine and ensures its continuous safe performance. Electrical systems have to be reassembled following National Fire Protection Agency (NFPA) codes 70 and 79 and Occupational Safety and Health Administration (OSHA) guidelines. CAD is used for the design of the electrical systems and includes identification numbers for devices, wire numbers, colors, and sizes.
There are several choices available for general controls during the rebuild process. The original set can be used after having been upgraded or controllers from other manufacturers can be chosen. The major vendors for controllers are Allen Bradley, Siemens, GE, and Square D. The controller has to match the processes performed by the machine and is chosen in accordance with its compatibility. The main concern related to the purchase of the controller is its price, which has to be included in the budget for the rebuild.
In the rebuilding process, there are two separate sections with one being the manual work of cleaning, scraping, polishing, painting, and the mechanical assembly of installing gears, screws, and other parts. The other section of machine rebuilding is the technical aspects that refer to the software and controllers, which are technological computerized components that require expertise and technical know-how.
During the rebuilding process, a PLC, programmable logic controller, or CNC, computer numerical control, will be used as the means for programming the operations of the machine. Of the various steps in the rebuilding process, the installation of a CNC or PLC controller is a highly technical process and is essential to the successful performance of the rebuilt machine.
Of the various aspects of the machine rebuilding process, the importance of the upgrade of the software tends to be a secondary consideration. Software design and structure determine the effectiveness of a machine after all the manual tasks are completed. CNCs and PLCs have software that instructs a machine to perform various functions. CNC software involves the use of codes based on a design created in CAD. PLC software controls the movements and functions of a machine.
The function of a PLC can stretch beyond the control of one machine and can include an ethernet connectivity for data collection and sensor monitoring. The many features of a PLC necessitates that their connection and installation be carefully monitored. Machine rebuilders may not always complete this function due to its technical nature, which requires machine rebuilding customers to hire certified professionals to complete PLC programming.
As with PLC software, machine rebuilders do not normally have CNC software experts with the appropriate set of G codes. In many cases, it is advisable to contact the manufacturer of a rebuilt machine to receive guidance in regard to the proper codes that fit the processes of a machine. Additionally, for a fee, CNC experts can train personnel regarding the installation of CNC operations. CNC controller manufacturers include NUM, Siemens, GE Fanuc, BWO, and Allen Bradley with Siemens and GE Fanuc being the best known.
Servo systems are the power behind the CNC command system and differ in accordance with their manufacturer. The selection of a servo system depends on performance, adjustability, and dependability. Their motors have to have the appropriate torque and speed to move the axes and should have sufficient and turning parameters. Servo motors have to be protected from the effects of the environment in which they operate since they are sensitive to the effects of dirt, oil, and coolant.
The final step in machine rebuilding is testing the machine during operation. The testing process involves making adjustments to the software, alignment, gears, and other moving parts to ensure a quality performance. It is during the testing phase that the success of machine rebuilding can be empirically observed. Testing provides the proof of the viability and success of the rebuilding process. An essential part of the testing phase is the documentation of the machine rebuilding process with an outline of each of the steps of the process.
The outline of machine rebuilding provided above is a simplification of the complexity of the process. Types of machines, manufacturing processes, and various other factors influence machine rebuilding and cannot be covered in a single article. The factors described are the basic attributes that have to be closely monitored to ensure the success of machine rebuilding. Although price is a factor to consider when making the decision to have a machine rebuilt, close attention to the services being provided and the technical skills of the provider are essential considerations even though they may extend the budget for the project.
Machine rebuilding takes a different form depending on the type of machine being processed. The extent of machine rebuilding covers a wide range of equipment from excavators and dump trucks to highly technical production CNC machines. Machine rebuilders assist their customers in evaluating the viability of rebuilding a machine. The timeline for when to rebuild a machine usually falls about 15 years from the time a machine was purchased new.
The option of rebuilding packaging equipment is ideal for improving productivity without having to endure the expense of new equipment. The rebuilding process is more expensive than doing simple repairs but more affordable than purchasing new equipment. The stress and demands placed on packaging equipment causes it to get out of alignment and lose its efficiency. Rebuilding enhances a packaging machine’s accuracy, efficiency, and speed with the additional benefit of savings over time.
The process of rebuilding a hydraulic press makes it possible to add new features with the most common being the addition of new technologies such as touch screen controls. The inclusion of various forms of robotics, like feeders, gives older equipment the feel of a new hydraulic press. Rebuilding hydraulic presses assists in bringing older presses up to modern day safety standards, which has become an ever-growing important issue.
The main goal of rebuilding a hydraulic press involves replacing electrical and hydraulic systems with modern components. Manifold systems are used in place of piping and valve systems to make troubleshooting and repairs easier. Hydraulic cylinders are rebuilt or replaced as well as the press motor and pumps. As with all machine rebuilds, platen guides and slides are replaced with new ones. Pipe thread systems are updated and replaced with oil ring seals that do not leak.
The rebuilding of a hydraulic press gives it new life and increases its years of usefulness. The subsequent effects are improved production and increased speed of output. The installation of modern control panels with status updates reduces labor costs and improves product quality.
The rebuild of a CNC machine is a complex and complicated process that requires disassembling the machine down to its individual components. Indications that a CNC machine needs to be rebuilt are increased downtime and the growing costs of repairs. With a CNC machine, the controller may be operating fine but the mechanical aspects of the machine may be experiencing wear and deterioration.
The complexity of rebuilding a CNC machine relates to the machine’s servo and spindle motors, drives, electrical components, and the machine’s software. In most cases, a CNC machine may be mechanically sound but need its control system replaced. This may necessitate a less intense rebuild at a lower cost.
The life of a grinding machine is limited because its accuracy and durability deteriorate. The amount of time between the installation of a grinding machine and its decline are dependent on the machine’s structure, its use, and how well it is maintained. When a grinding machine is down 20% of the time, it creates work stoppages and requires adjustments and repairs that slow production and interfere with scheduling.
Rebuilding a grinding machine includes a complete disassembly of the machine to evaluate the machine’s electrical, pneumatic, and hydraulic systems. For the best results, OEM parts are used and include every nut, bolt, rivet, hose and pipe. As with CNC machines, grinding machines are updated with the latest technologies including monitors, LED lighting, and controls.
The cost of rebuilding a grinding machine is approximately 75% of the cost of purchasing new. The timing of the rebuild can vary between four or five years up to 15 years depending on how many shifts per day the machine is used. Ones that are in use for three shifts over 24 hours per day may need to be rebuilt in four to five years.
The rebuilding of a lathe begins with disassembling the machine and sandblasting all the parts to remove debris, paint, and coatings. Headstock, gearboxes, and aprons are hand stripped to avoid sandblasting dust from getting into the bearings. All of the parts are coated with polyester resin to create a hardened subbase for the painting process. After being coated, the parts are sanded and painted.
The lathe bed is way ground to ensure that the surfaces are aligned and make even contact. After the way grinding, the bed is touched up and painted. Material is milled off the bottom of the saddle. Bonding material is added to the bottom of the saddle to bring it above its normal location and hand scraped to bring it to its factory spec height. This process brings the saddle into proper alignment with the feed shafts and lead screw where they pass through the apron. The saddle is placed on the bed and slid back and forth multiple times to locate high spots that have to be scraped such that the saddle makes proper contact with the bed.
The final step in lathe rebuilding is to put the machine through several tests. A common test is to cut a workpiece using a 3-jaw chuck. For a rebuilt lathe to pass the cutting test, it must be able to hold 0.0001 per inch for a 4-inch cut and have a good surface finish. If the finish is poor, the spindle bearings may need to be replaced.
The few machine rebuilding examples listed above are a small representation of the machines that rebuilders can refurbish back to new. Although machine rebuilders are capable of working on any form of machine, many of them specialize in a particular type and have the parts, experience and expertise necessary to bring their types of machines up to original factory specs.
Mazak USA is a manufacturer of technologically advanced machines capable of a wide range of machining functions. The precision of Mazak USA equipment makes it possible to achieve the tightest tolerances with ease and accuracy. With a PCL interface and hybrid engineering, Mazak USA machines offer the maximum in performance and eliminate the need for secondary processing.
The Integrex i-400ST AG is a multi-tasking machine that is versatile and offers maximum throughput. It combines high powered turning and full function machining to produce parts in a single setup. The Integrex i-400ST AG has a second turning spindle and lower turret to minimize fixtures, tools, handling, and non-cut time. The technological innovations of the Integrex i-400ST AG significantly reduces lead times and provides exceptional accuracy, which eliminates the multiple steps to producing and machining a workpiece.
The Mazak Integrex e-500H Multi-Tasking Machining Center is capable of completing turning, milling, boring, and drilling in one machine setup with exceptional accuracy. The machining center is capable of machining heavy components, large diameter parts, and shaft type workpieces for a wide range of industrial applications. The Integrex e-500H Multi-Tasking Machining Center is equipped with a high output spindle motor with two gear ranges for heavy duty machining and a drop worm system for positioning accuracy. It has a 50 taper single turret with an automatic tool changer and a heavy duty cam on the B axis for tool agility.
The Variaxis i-1050 has 5-axis machining capabilities for processing large, intricate, and complex parts in a single setup. Unlike other forms of CNC machining, the Variaxis i-1050 is capable of machining workpieces with significantly thin surfaces with exceptional accuracy and tolerances. It has a 50 taper milling spindle with standard, high speed, and high torque versions available. The trunnion unit of the Variaxis i-1050 supports the rigid tilting rotary table on both ends, a design that does not interfere with milling operations. The high speed of the Variaxis i-1050 is due to the roller gear cams on the swiveling A-axis and the direct drive motor of the rotary C-axis.
The Mazak Mega Turn 900S is a vertical CNC turning center designed for cutting large, low to medium profile, tough to machine workpieces and is designed for removal of material from heavy metals such as stainless steel, titanium, and other alloys. The efficiency and design of the Mega Turn 900S is an excellent means for improving throughput, reducing machining time, and increasing profitability.
Repairing a Mazak machine tool, such as a Mazak Computer Numerical Control (CNC) machine, is a complex and specialized task that requires the expertise of a trained professional technician or engineer. A skilled professional is essential to ensure the safety, functionality, and longevity of the equipment.
Lack of Knowledge and Experience: If you do not have experience or proper training for working with Mazak equipment, it's best to leave the repairs to qualified professionals. Attempting repairs without the necessary expertise can lead to further damage and safety hazards.
Complex or Critical Components: Mazak machines often have intricate and critical components, such as CNC controls, spindle systems, and precision ball screws. Repairing or calibrating these components requires specialized knowledge and equipment.
Safety Concerns: If you encounter a situation where safety is compromised, such as electrical issues, coolant leaks, or structural problems, it's imperative to contact a professional immediately. Safety should always be the top priority.
Warranty and Service Contracts: If your Mazak machine is under warranty or covered by a service contract, attempting to repair it yourself could void these agreements. Professional technicians authorized by Mazak should handle covered repairs to maintain warranty and service contract validity.
Diagnostic Challenges: When you're unable to pinpoint the exact problem or error with the machine, it's a clear sign that you should consult a professional technician. They have the tools and expertise to perform comprehensive diagnostics.
Availability of Spare Parts: If the repair requires replacement parts that are not readily available or that you don't have access to, it's best to rely on professionals who have access to Mazak's authorized parts suppliers.
Specialized Tools and Equipment: Many Mazak repairs require specialized tools and equipment for disassembly, calibration, and testing. Professionals have access to these tools and are trained in their use.
Minimizing Downtime: Professional technicians are often able to diagnose and repair issues more efficiently, reducing downtime for your operations. This can be critical for businesses relying on Mazak machines for production.
Manufacturer Expertise: Mazak's authorized service technicians have in-depth knowledge of Mazak machines, including the latest models and updates. They can provide the most accurate and up-to-date support.
Legal and Liability Concerns: If you attempt to repair the machine yourself and inadvertently cause damage or safety issues, you may be liable for the consequences. Professional technicians carry insurance and certifications to protect both you and your equipment.
Preventive Maintenance: Besides repairs, professional technicians can also perform preventive maintenance to keep your Mazak machine in optimal condition, reducing the likelihood of breakdowns.
Working on complex machinery, like Mazak machines, requires specialized knowledge. Unless you have the necessary expertise, tools, and access to authorized spare parts, it's usually best to seek professional help for Mazak machine repairs. This ensures the safety of personnel, the integrity of the machine, and the protection of warranties or service contracts.
In many cases, there is confusion regarding the difference between retrofitting, rebuilding, and remanufacturing. The three terms are commonly used interchangeably but involve slightly different processes and functions. Additionally, the difference between the terms defines how a machine will be changed and altered once it has been reworked.
Retrofit refers to replacing a machine’s tool control system, which includes changing a machine’s drives, axis motors, and spindle motor. The complete process is performed at a customer’s site. It includes the modification of an existing older machine by adding new features and updating the machine. Included in the updating process is adding some degree of automation to enable the use of older machines as part of modern production methods.
Benefits of retrofitting:
Rebuilding refers to a wide array of processes, operations, and functions that are designed to restore or replace various components of a machine and upgrade its appearance such that it looks like it is brand new. The process of rebuilding includes a long list of factors that will be improved on a machine and can include major systems and simple switches, hoses, bolts, and belts. The goal of rebuilding is to bring a machine back to its original condition in accordance with its design specifications. Rebuilders use the diagrams, provisions, and stipulations of the original manufacturer to bring a machine up to full efficiency.
Benefits of rebuilding:
Although remanufacturing may have similarities to rebuilding, it is a much more aggressive process that includes replacing major systems and engineering improvements and alterations to enhance the productivity and efficiency of a machine. An old manual machine can be converted to a CNC machine by increasing spindle speed, adding a tool changer, increasing table size, and installing additional axes.
Remanufacturing is a cost-effective alternative to purchasing a new machine. It involves taking outdated and old machines and transforming them into high tech modern pieces of equipment with the latest technology.
Benefits of remanufacturing:
The wear and tear on production machines can produce challenging problems that have to be resolved by expert technicians and engineers. Astro Machine Works has the talent, skill, and expertise capable of taking on the challenge of any form of machine repair or rebuild. The company reverse engineers components to bring them up to manufacturer specs in a timely and cost-effective way. Every step of the rebuilding process is clearly outlined for customers in order to restore a semi-functional machine to its original manufacturer’s standards.
Machine Rebuilders are experts in rebuilding over 130 different types of machines including lathes and milling machines. The company is an authorized dealer for Centroid and FANUC CNC controllers and are experts in rebuilding CNC machines and integrated systems. Machine Rebuilders has a staff of engineers, electricians, mechanics, CNC control technicians, and researchers capable of providing their customers with the best choice for resolving their industrial machine issues. The company rebuilds machines on site or at their facility in New Derry, PA.
Precision Service dedicates itself to restoring machines to their original capabilities by cleaning, repairing, and replacing critical machine parts. The company’s skilled technicians transform ineffective and old equipment into rejuvenated and new vital equipment for production processes. Precision Service offers the ability to extend the useful life of a machine by paying close to the minute details associated with a successful machine rebuilding process. The company specializes in rebuilding CNC lathes, turret lathes, toolroom lathes, and grinders and grinding lathes. Precision Services has the talent, knowledge, and skill to rebuild machines to their highest capabilities.
KRC provides a complete tool overhaul to bring a machine up to its original specifications. Every aspect of a machine is cleaned, checked, inspected, cleaned, and rebuilt, using re-machined and new parts. KRC helps with rebuilding boring mills, gantries, and bridge mill machines. The company has the special ability to assist with mechanical difficulties and CNC control problems. KRC provides technical and rebuild services for 16 of the most popular brands of machines including Toshiba, Mario Carnaghi, and SNK.
The staff at WIMS are experts in machining, CNC operations and programming, and various types of repair services. WIMS has been successful due to its ability to form a close working relationship with its clients. The close ties the company has developed over the years has led to the success and high performance of their rebuilt equipment. Using the highest quality tools and procedures, WIMS rebuilds all machines to meet performance standards that are typical of new pieces of equipment. Machines are meticulously examined and evaluated to ensure the rebuilding process is flawlessly completed.
The process of machine rebuilding is a way to modernize outdated equipment. When equipment requires continuous repairs and creates extensive downtimes, the tendency is to abandon old equipment and purchase new. Although this may seem to be a logical alternative to an ongoing problem, there are solutions that are less costly and help maximize the use of available resources.
Machine rebuilding is a dynamic and aggressive method for refurbishing old out of date equipment and adding technological features. Additionally, replacing old equipment with new can be excessively expensive in today’s market. Machine rebuilding can cost about 75% of the cost of a new piece of equipment and helps avoid the problems associated with disposing of old machinery.
The profitability of an industrial operation is dependent on the control of fixed costs. One of the most expensive fixed costs is the equipment used to produce products and parts. Repairs, updates, and downtimes can be a disproportionate amount of a manufacturer’s budget. Controlling such costs is at the center of a manufacturing operations profitability.
Machines that have been in constant use for 15 years tend to look worn and dilapidated, which may inspire the need to replace them. Machine rebuilding offers an alternative to purchasing new equipment and can keep equipment costs down. Although it is a lengthy and complex process, machine rebuilding takes equipment that is 10 or 15 years old and brings it into the modern era at approximately 75% of the cost of new equipment. Regardless of the appearance of a machine, machine rebuilding can make it perform and appear like new.
Due to the nature of the machine rebuilding process, rebuilt machines receive a more thorough inspection than even new machines. Every piece, part, bolt, screw, and component are inspected for their viability and performance. If a part is found to be damaged or worn, it is replaced with a new one while components that are still sturdy are cleaned and refreshed.
The inspection process is one of the factors that machine rebuilders rely to demonstrate the quality of their work. While machine manufacturers assemble machines with new parts, little is done to examine the individual parts as they are placed on a machine, the performance of which is judged by how the machine operates during pre-shipment inspection.
The 21st century has given birth to the era of rapid technological advancements and equipment improvements. Very few industrial processes operate without the use of some form of electronic control system, which was not available over ten years ago. These innovations have made older equipment seem outdated and inferior, a belief that can be changed by having a machine rebuilt.
Old equipment that is functioning properly without technological enhancements can be modernized during the machine rebuilding process. Old presses, lathes, and mills can have controllers added, CNC coding, and PLC programming. Machine rebuilders have all of the tools and expertise to change an old worn press into a modern high efficiency CNC operated press.
The rebuilding and improvement of old equipment avoids the need to trash equipment that can still perform. Although old equipment may not end up in a landfill, it can still end up stored in a building as waste material and unused. Sustainability has become a key aspect of modern business. Every business is working to ensure the success and continuance of the planet. Taking advantage of available resources and transforming them into new equipment is a major part of the sustainability effort and an essential component of machine rebuilding.
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