2 major repairs on the CNC lathe after crash. Mazak Integrex spindle repair. 

Thanks!

Thanks! Well, it was really fun so don't you miss it if you get an opportunity :)

Thank you for those kind words! It was quite fun, except paying for the overpriced parts.. Luckily (or unfortunately) there are alot more repairs that needs to be done to the machine which i look forward to, but I also have alot of upgrades and modifications that I'll do to the machine.

Yeah that machine is way to expensive and important to skip that part.

You doing duggas? I have to settle for an "elbow-tremble".

Elbow-tremble is not to be underestimated. I've heard they are on par with a high quality torque wrench :)

Thank you! Yeah, I should have thought about that when torquing the coupling. As soon as I started torquing the bolts, I remembered that they were only going to 17 nm, so I figured the capto could handle it even if it was not properly seated :) I didn't show it in the video, but I lubricated them before I assembled everything. You might see that they were a bit shiny when I was doing the reassembly. I don't know what Mazak says about it. Don't have any of the documentation.

Why won't they sell parts? I had no problem buying these from them. I got the BOM anyway, so I can find most items from other places. I thought that the repair was quite fun. Just a pain in the back from leaning into the machine, and a big camera right where I wanted my head was maybe not so fun... Yeah, I do have a little bit of a wobble in the capto taper, but not much. I am considering fixing the spindle bearings and the bevel gear some time in the future. Considering going all the way and sending the spindle off for a regrind.

@@Rydermanmakes The machinery I usually get/can afford for slightly above scrap price are usually 15-20years older than your Integrex. Nothing with factory parts on these any more, either you fix it or you make replacement part yourself or the machine is dead.

Ah ok. Yeah that is a tough one. Guessing parts for those have not been in stock for a long time. I thought you meant that you were not allowed to buy parts. For the first 3 years, I could not buy parts from mazak for my machine since it was not registered to me. I know that haas wont sell some components but instead requires it to be installed by a Haas tech.

Thank you!

Thanks! Not sure if it's mark 2. It's from 2001 at least.

@@Rydermanmakes Mark III and newer have a direct drive millspindle without gears or hirth coupling. How fast can this mill spindle run? 8000rpm?

It's a 6000 rpm but i rarely run it more than 4500, since it's so noisy. Either the spindle bearings or the bevel gears. Thats why I might replace both in a not to distant future. Also kind of ruins the filming with all the noise (if you've seen any of my other videos). However, i've looked through all the drawings and everything is identical between the 6k and 10k versions, so i might have a look if it cant be boosted in the machine parameters. The only thing i have not yet checked is the driver for the milling spindle. if mark 3 didnt have the hirth coupling, how did it lock the spindle for turning?

@@Rydermanmakes Ha, i maybe was accidently lying. Im sure about the machines with a b2-axe (able to do interpolation turning) but i guess up to mark4 (12000rpm) they maybe could have kind of hirth.... but if, it looks totaly different. I never had to disassemble an integrex mill spindle, so i only could tell it exactly after i studied the blueprints. The think i-Series has some kind of hydraulic ring clamping segment (same on the b-axe) what is absolutely strong and precice. Sorry for not having reliable details at the moment. I will investigate, after my vaccation ends.

I don't know if I can do any interpolated moves with the B axis. Someone told me once that my machine can only do indexing moves. Anything you know about? I have all the drawings for the entire machine and BOMs and looked at them quite a bit. The rear end of the turret looks quite simple, so shouldn't be to much of a problem, unless there is some suprise, like components that require fixtures or parts that are shrink-fit.

Hehe yeah I've got sets of those. I just wanted to take it slow. Didn't know what suprises was waiting for me, since i knew from before how badly the precious owners had done some repairs. Also quite a lot of precision surfaces on those components that i wanted to be careful with.

I did use one at the end of the flattening, but I just forgot to film it. You can see it in the background in one of the shots.

Yeah it's an absolute beast. Quite complex, but that spindle nose is just the tip of the iceberg. Got more videos coming when I repair and upgrade behind the turret.

Thank you! I can usually get e repeatability within 2 micrometers if the material doesn't have a lot of internal stresses, when the machine is running part after part. If I'm running a one-off part and I'm sneaking up on a critical diamter, i can usually get it within 1-2 microns in materials that are easy to machine, but steel and stuff that has a bit of springback usually gets me within 2-3 microns. But there are a lot of variables to this, such as material, internal stress in it, stock size, stickout from the chuck, huw much of the stock that's being removed, insert grade and so on.

Yeah the capto toolholding system. Best system there is (except the price).

@@Rydermanmakes Well i think the price is just the thing of it being not so easy to create

Yeah grinding such a perfect match between the taper and the flat face is not easy. Especially when tools should have a repeatability of 2 micrometers, according to Sandvik.

@@Rydermanmakes Not a big deal to do polygonal grinding, almost any CNC cylindrical grinding machine can do this (but tool manufacturers probably do not use "any" machine). The trick is they constantly measure the polygon size while grinding (without interrupting the grinding process) at a given distance from the flange.

Yeah that's what i meant by getting those two surfaces perfectly matched. I think Sandvik invented it in the 80s. Guessing it was a bit more tricky back then.

Slightly difficult when the lathe is the machine being repaired. The area I'm grinding doesn't have a bolt nearby, so it will stay flat when everything is assembled.

When I bought it, about 7 years ago, it was about $60K. Not sure of the market today.

I have seen old Integrex machines cost 100k.

As old as mine? 2001? That's crazy. I felt like I was paying a bit to much for mine.

@@Rydermanmakes pretty close to 2001.

Here is how it works. If you look at 10:10, there are 8 holes with O-rings around them. 2 air, 4 coolant and 2 hydraulic oil for the coupling. At 9:07 you can see a small hole in the side of the cylinder wall (next to the top edge, between my hands). In the next clip a few seconds later, you can see the other hole a few centimeters to the right, lower down in the cylinder. That's how the oil goes to the middle ring. In the same clip, you can see that the middle ring has 4 threaded holes. That is the surface that the hydraulic force is action upon, to engage the coupling. It's not much, maybe 15-16 mm wide, but still maybe 40kN of axial force. A few seconds later, when I put the O-ring in place on the middle ring, you can see there is a lip underneath it, maybe 2mm wide. That is the surface that the hydraulic force is acting upon to push the middle ring forward, to disengage the coupling. I kind of regret not including this in the video. Was close to include a picture of the drawing of this entire assembly, but for some reason I skipped it. Unfortunately there are several more things that need to be fixed with this machine. At least it's fun fixing it and making videos about it :) Yeah, I have no idea why it sounded like I said eight. Must have been running low on coffee :)

@@Rydermanmakes now I can see that the 4 threaded holes are blind so oil cannot get that way. I have worked with hydraulics for many years and am a machinist so I have seen many systems. it was the 4 threaded holes I couldn't see didn't go through the whole thing,,

Yes but that would not have made a difference.