1 Kugel Rotary estimating and quote process

Simplified summary of the quote process:

• We can provide an upper and lower estimate within one day.
• We may need to complete a strip-down to inspect for internal damage and be certain of the bearings and component types.
• If we do this, we will ask you for permission to proceed
• We reserve the right to charge a nominal fee of £300 for the inspection report.
• Once we have had chance to inspect the spindle, we will be able to provide a firm quotation.
• You are not obliged to order, the cost of the inspection report will be deductible from your next order.
• We aim to provide a strip-down inspection and quote within five working days.

2 Pre-estimate

2.1     What we need from you at this stage:

• The machine and spindle make, model and serial number.
• The size and (approximate) weight.
• The maximum and typical running speed RPM.
• The tool interface type.
• Although not essential any additional information you have will help us.
  • Lifetime, installation date, running hours, number of tool-change cycles.
  • Bearing part numbers and configuration.
  • Approximate cost of new (to determine if beyond economical repair).

2.2     The service we provide:

• We are happy to provide phone support to help you diagnose if you have a spindle fault and any potential solutions, this is included in the service.
• If your spindle is seized, has run-out or other damage it is likely to need repair.
• It is very difficult to determine the repair cost without an inspection, we can give you a guide price over the phone. It is worth noting that spindles with a value of <£1,000 are rarely economical to repair an a typical repair cost is between 25% and 70% of the cost of a new spindle.
• We can visit you (in the UK), ask us to quote for a breakdown callout.

3 Initial estimate

3.1 What we need from you at this stage:

• To ship the spindle to our factory.

3.2 The service we provide:

• As standard we assess and provide a spindle condition report:
  • External inspection, noting condition and damage.
  • Basic spin test.
  • Tool interface runout.
  • Electrical checks of winding resistance, earth continuity and insulation.
• As a options we can:
  • Provide a bearing vibration analysis, drawbar force test or additional testing before disassembly (as for a quote)
• We will provide:
  • A bracketed estimate, based on previous and typical failure modes. This will be as accurate as possible, but as we haven’t yet disassembled the spindle it is non-binding.
  • An assessment report.
  • Confirmation that we can repair, and a recommendation to proceed (or not).
  • We aim to do this within a day of receipt.

3.3 What we need to proceed:

• If you are happy, we need Permission to Proceed (P2P).
• We will provide you a quote for £300 for the disassembly report, this will include a £300 voucher to spend on this, or subsequent orders.
• The spindle will be disassembled, measured and we will obtain quotations from our component suppliers.
• There is no obligation to proceed, but:
  • After disassembly it is advisable to scrap components such as seals and bearings.
  • The spindle will be returned in its disassembled state.
  • We will require a purchase order for £300
• We will provide a detailed quotation of price and lead time(s).
• We aim to do this within 5 working days of receipt.

3.4 Alternative option

• We recommend the disassembly report, as it is fully transparent and minimises risk of unexpected cost for both you and us.
• However as an alternative option we can proceed on an ‘estimate plus’ basis. We will provide a best-case quotation (this will include the standard components replaced on almost every re-manufacture: typically, bearings, seals, screws and fasteners, and the inspection/assembly/test labour).
• We will then proceed with the refurbishment, at your risk, so there may be additional items that require replacement, and we will itemise them and bill you.

4 Disassembly report

4.1 What we need from you at this stage:

• Permission to Proceed (P2P) and either Purchase order or written agreement to pay £300.

4.2 The service we provide:

• Once we have P2PPermission to Proceed, we provide a spindle disassembly report.
  • This will detail bearing and component types
  • Components beyond economical repair, and measurements or test information
  • ‘Advisories’ wear or slight damage that could optionally be addressed during the service will be noted as additional line items
• We will provide a detailed quotation with price (valid for 30 days) and lead time (an upper estimate, you will receive a confirmed ship date when we receive the order. At this point we will order the components and schedule a production slot).
• A warranty period will be specified on the quotation

4.3  What we need to proceed:

• A purchase order.
• As standard we scrap worn/damaged components. If you would like them returned to you feel free to ask.

5  Assembly and test report

• As standard we clean and inspect every component.
• We measure and test components during assembly.
• We measure and set the assembly to original tolerances.
• We run-in the bearings, at increasing speed increments whilst monitoring temperature and/or vibration.
• We perform a suite of final tests and provide a detailed test report.
• If additional issues or fault components are identified, we will replace that at our cost honouring the original quote.
• We intend to deliver on-time, every-time. If issues arise during assembly or testing, we will keep you informed and provide an update on your ship date.
• We prove a warranty.
• We will securely package.
• If the quote is inclusive of shipping, we will arrange this on your chosen delivery date.

6  P2P form – Permission to proceed

Name:

Date:

I provide permission to proceed and prepare a disassembly report.

I understand that:

• This will cost £300, payable by purchase order, either separately or on the full repair invoice.
• It is inclusive of a £300 voucher to spend on this, or subsequent orders.
• There is no obligation to proceed, but:
  • The spindle will be returned in its disassembled state.
  • Some components (typically, but not limited to, bearings and seals) will be in an unusable condition.
  • We ensure the goods are kept in good condition:
    • Segregate from all other goods so they remain identifiable
    • Not remove, deface or obscure any identifying marks
    • Maintain the goods in satisfactory condition and keep them insured for their full price
    • Refer to our full terms and conditions

Machine tool make / model
Spindle tool make / model
Spindle Serial number (if known)
Description of fault (use the fault diagnostic form)
Spindle speed
Motor controller type
Application (milling, grinding, etching…)
Materials, and grade if known (aluminium, steel, plastic, composite…)
Cooling fluid
Hydraulic operating pressures
Digital feedback (limit switches, etc…)
Analogue feedback (encoder, thermocouple, tool position, vibration…)

7 Failure mode

General fault description (what is the effect > the symptoms > what do you think the cause might be?

When did it start / how long has it been an issue?

Is it permanent or intermittent? Is there anything that switches it on-off?

Anything else that might help us with repair and diagnosis?

7.1 Fault finding chart

Not all spindles will have all of the features in this checklist – just mark N/A for not applicable or X for unable to check.

We are happy to provide phone support or mor details on the check procedure (although every spindle and machine is different!).

Symptoms	Cause	Check	Results and Comments
Noise/vibration	Total Bearing failure	Does the spindle spin? If so is there resistance or noise when slowly rotated.
	Bearings failing	What is the motor load, is this higher than normal (idling, accelerating and cutting)
		Describe the noise (high pitched, rumbling, only when cutting).
		Allow the spindle to cool, run and monitor bearing temperatures
	Tool holding	Wear in the expanding mandrill/clamping jaws, clean, and if possible replace.
		Check the tool clamp position and/or clamp force. If possible, inspect the drawbar.
Burning smell	Friction between components	Stop. Is there resistance or noise when slowly rotated.
	Electrical short	Electrically Isolate. Measure resistance between earth and each motor phase.
Noise when tool changing	Tool changer to spindle  alignment.	Check the tool taper for uneven wear (egg-shaped runout). Check alignment of the tool loading arm.
Tool breakages	Runout	Change the tool holder/collet Perform the checks below.
Surface finish	Runout	Are the tool interface & air purge holes clean and free of burrs or damage (clean or gently stone/polish)
		Measure the radial runout (using a dial test indicator on the inner bore of the tool taper, typically <5 µm is good, >10 µm requires investigation.
		Measure the axial runout (face of the tool taper).
		Measure the projected runout (typically requires a gauge bar, but a new/known good tool or bar extension will be sufficient as a guide).
Damage to the spindle nose/housing	Machine ‘crash’ spindle-contact at speed	Check for physical damage/dents/impact marks. There may be unidentified bearing damage following a significant ‘crash’
Electrical and feedback faults	Damaged cabling/wiring	Inspect the cabling for damage, check
	Damaged plugs/pin	Check plugs for contaminate (fluid, swarth).
	EMC interference	Check bonding and cabling of the machine/motor/drives etc…
Fluid leaks	Cutting fluid – Hydraulic coupling	Spindles with through tool air or coolant will have a rotary coupling (typically at the rear of the spindle) inspect.
	Hydraulic oil – tool change drawbar	Note any oil building up or seeping.
	Cooling fluid – Cooling system	Many spindles have a water cooled jacket for the motor and bearings. Check for seeping. Low pressure air leak test.
Accelerated wear	Abrasive material in cutting fluid	Note the cutting material(s). Perform a check of the cutting fluid and filtration.
	Blocked air purge	Most spindles have at least 2 air-purge systems: -Labyrinth seals between the housing and rotating shaft -Cleaning air purge holes in the tool taper/face. Clean, check each is clear.
Air leaks	O-ring failure	See above, most spindles only require an air supply for clean/purge and by design this is exhausted to atmosphere. Flow through test (sufficient flow rate for purge – if not clean purge holes) Or low pressure air leak test.