This article contains everything you need to know about machine rebuilding and its importance to manufacturing
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Machine rebuilding involves dismantling a machine, repairing or replacing its components with OEM (Original Equipment Manufacturer) parts to restore it to its original specifications. This process includes thorough cleaning, repairing, and rebuilding each part, ensuring that every detail is addressed. The goal is to make the rebuilt machine perform as if it were brand new, meeting all original standards and specifications.
In manufacturing, reliable machines are crucial for processing and producing essential parts and components. Over time, machines can degrade, become outdated, or fall behind in technology. While replacing equipment with new models may seem like a viable option, rebuilding can offer a cost-effective alternative to restore machines to their peak performance.
Machine rebuilding provides a cost-effective option for maintaining valuable and dependable equipment rather than replacing it with new models. Rebuilders offer advanced technological solutions to upgrade and sustain existing machines that have demonstrated their worth over the years. This intricate process evaluates every function of the machine, ensuring it is updated to current standards.
Machine rebuilding involves more than just addressing immediate issues, unlike machine repair, which focuses on quickly fixing a specific problem. In a repair scenario, technicians identify and correct the immediate malfunction, much like applying a bandage to a wound.
Machine rebuilding, on the other hand, is a thorough and comprehensive process. It involves a complete overhaul, examining every component of the machine, down to the finest details, and updating it to incorporate the latest technology. A rebuilt machine essentially looks and performs as if it were newly manufactured, ready for many additional years of reliable service.
During the rebuilding process, every facet of the machine is carefully inspected. This includes mechanical functions, hydraulic systems, lubrication, pneumatics, electrical components, controllers, and coolant systems. Each system is disassembled, cleaned, examined, tested, and either repaired or replaced to ensure the entire machine operates as efficiently and effectively as possible.
For a machine to be effectively rebuilt, it must first be disassembled into each individual component and part. This process involves a thorough cleaning and inspection to assess damage and wear. The disassembly stage includes breaking down the machine and evaluating the extent of wear and damage accumulated over its operational cycle. Every part, regardless of its size, importance, or location, is examined meticulously—nothing is overlooked.
The cleaning phase allows for a detailed inspection of each part for deficiencies, defects, and wear, and prepares them for the painting and reassembly phases. During disassembly, images of each component are scanned, saved, and categorized. This scanning process facilitates quick and efficient reassembly of the machine. It also ensures that, upon completion of the rebuild, the machine will be reassembled according to the original manufacturer's design and specifications.
The guideways of a CNC machine are crucial components that dictate the movement of the machine's tools along its axes. They consist of a carriage mounted on a rail that drives the cutting tool or table. Due to their importance, disassembling and refinishing guideways is a critical part of the machine rebuilding process. The method of refinishing guideways varies based on the machine's design, configuration, and structure.
Cleaning guideways involves a manual process of hand scraping to ensure the surfaces are even and smooth. This delicate procedure requires specialized skills developed through extensive training and practice. The effectiveness of hand scraping is determined by achieving the proper bearing area and alignment, with bearing areas exhibiting 10 to 15 contact points per square inch and overall contact ranging from 50% to 60%.
Modern CNC machines are equipped with guideways that eliminate the need for scraping, often featuring a low-friction material like SKC3, Moglice, or Turcite on one of the contact surfaces. If necessary, the coating can be renewed, and the guideways can be reground, polished, and realigned. For guideways that utilize a linear bearing assembly on a hardened linear rail, a full replacement with a new guideway is required.
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.
Components subject to wear, like bearings, bushings, seals, and wipers, should always be replaced rather than repaired. The only exception involves parts that experience minimal movement during machine operation and are expected to remain in top condition. However, this exception does not cover rubber or felt items like seals or wipers, which should be replaced without exception. Lined components such as clutches and brakes should also be replaced as a precautionary measure, as they are typically sealed and difficult to inspect thoroughly.
Machines involved in gear production incorporate gears within their own mechanisms. These gears are in constant motion during machine operation, leading to wear on the teeth, bores, and keyways due to the persistent stress. The most crucial gears within a machine are responsible for controlling the rotation of the worktable and the cutter. Wear and tear on these gears can be reflected in the quality of the gears produced by the machine itself. It is vital to meticulously inspect the gear spacing and tolerances within the cutter spindle assembly and worktable as part of the machine's rebuilding process. During reassembly, it is crucial to precisely adjust the gear lash, as excessive lash can result in damage to the gears that the machine produces.
Alignment verification is essential at every stage of the reassembly process. Maintaining the parallelism and perpendicularity of the axes is critical as the guideways are refinished and the machine is powered up. The International Organization for Standardization (ISO), Deutsches Institut für Normung (DIN), and the American National Standards Institute (ANSI) have established permissible tolerances for these alignments. Additionally, machine manufacturers provide specific tolerance guidelines for their equipment, which should be followed closely during reassembly.
Among the various systems in a machine, the electrical system is the most vital, as it governs the machine's operations and ensures safe, continuous performance. The reassembly of electrical systems must comply with National Fire Protection Association (NFPA) codes 70 and 79, as well as Occupational Safety and Health Administration (OSHA) regulations. The design of electrical systems typically involves CAD, which includes detailed identification for devices, wire numbers, colors, and sizes.
During the rebuild, there are multiple options for general control systems. The original controls can be retained and upgraded, or new controllers from various manufacturers can be selected. Major suppliers of controllers include Allen Bradley, Siemens, GE, and Square D. The chosen controller must align with the machine's specific processes, and compatibility is a key consideration. The primary concern when selecting a controller is its cost, which must be factored into the overall rebuild budget.
The rebuilding process can be divided into two distinct phases. The first phase involves manual tasks such as cleaning, scraping, polishing, painting, and mechanically assembling components like gears, screws, and other parts. The second phase focuses on the technical aspects, including the integration of software and controllers, which are advanced computerized systems requiring specialized knowledge and skills.
As part of the rebuilding process, a Programmable Logic Controller (PLC) or Computer Numerical Control (CNC) system is implemented to program the machine's operations. Installing a CNC or PLC controller is a complex, highly technical task that is critical to ensuring the rebuilt machine functions optimally.
While the upgrade of software might seem like a secondary concern, it is crucial to the overall success of the machine after all manual tasks have been completed. The design and structure of the software play a key role in determining the machine's effectiveness. CNC software uses codes derived from CAD designs, while PLC software is responsible for managing the machine's movements and operations.
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 play a crucial role in CNC programming and vary based on the manufacturer. Choosing the right servo system involves evaluating its performance, flexibility, and reliability. The motors must provide the necessary torque and speed to move the axes effectively and meet specific machining requirements. Additionally, servo motors need protection from environmental factors like dirt, oil, and coolant, as they are particularly vulnerable to such contaminants.
The concluding phase of machine rebuilding involves operational testing. This stage includes fine-tuning the software, alignment, gears, and other moving components to guarantee optimal performance. The effectiveness of the rebuilding effort becomes evident during testing, as it provides tangible proof of the process’s success. An integral part of this phase is the thorough documentation of the rebuilding steps, detailing each aspect of the process for future reference.
The overview of machine rebuilding presented here simplifies the intricacies of the process. Various machine types, manufacturing methods, and additional factors significantly impact the rebuilding process and cannot be fully addressed in a single article. The elements discussed represent the fundamental aspects that must be carefully managed to achieve successful machine rebuilding. While cost is an important factor when deciding to rebuild a machine, it is equally crucial to evaluate the quality of services and the technical expertise of the provider, even if these considerations require a higher budget.
Machine rebuilding varies based on the type of equipment being addressed. The scope of rebuilding can encompass everything from heavy machinery like excavators and dump trucks to sophisticated CNC production machines. Rebuilders help clients assess whether it’s feasible to undertake a machine rebuild. Typically, the decision to rebuild is considered approximately 15 years after the machine was originally purchased.
Rebuilding packaging equipment offers a cost-effective way to boost productivity without the high cost of new machinery. While rebuilding is more costly than basic repairs, it is generally less expensive than buying new equipment. Packaging machinery often suffers from misalignment and reduced efficiency due to the stresses and demands of operation. Rebuilding a machine can significantly improve its accuracy, efficiency, and speed, while also providing long-term savings.
Rebuilding a hydraulic press allows for the integration of new features, such as advanced touch screen controls and various types of robotics like feeders, which can rejuvenate older equipment to resemble modern presses. This process also helps update older presses to meet current safety standards, which are increasingly critical.
The primary objective in rebuilding a hydraulic press is to upgrade electrical and hydraulic systems with contemporary components. Manifold systems replace traditional piping and valve setups to simplify troubleshooting and repairs. Hydraulic cylinders are either rebuilt or replaced, along with the press motor and pumps. Additionally, platen guides and slides are replaced, and outdated pipe thread systems are upgraded to oil ring seals to prevent leaks.
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.
Rebuilding a CNC machine is a detailed and intricate process that involves completely disassembling the machine into its individual components. Signs that a CNC machine may require rebuilding include increased downtime and rising repair costs. While the machine’s controller might function correctly, its mechanical parts may be suffering from wear and tear.
The complexity of CNC machine rebuilding encompasses various elements, including servo and spindle motors, drives, electrical components, and software. Often, a CNC machine may remain mechanically robust but require an update to its control system. In such cases, the rebuild can be less extensive and more cost-effective.
A grinding machine's lifespan is finite due to diminishing accuracy and durability over time. The duration before a grinding machine shows signs of decline depends on factors such as the machine's design, usage, and maintenance practices. When a grinding machine experiences downtime of 20% or more, it leads to work stoppages and necessitates adjustments and repairs, which can disrupt production and scheduling.
Rebuilding a grinding machine involves thoroughly disassembling the equipment to inspect and overhaul its electrical, pneumatic, and hydraulic systems. For optimal results, OEM parts are used, including all nuts, bolts, rivets, hoses, and pipes. Similar to CNC machines, grinding machines are upgraded with the latest technologies, such as advanced monitors, LED lighting, and modern controls.
The cost to rebuild a grinding machine is roughly 75% of the cost of purchasing a new one. The timing for a rebuild can vary significantly, ranging from four to five years up to 15 years, depending on the machine’s operational intensity. Machines operating three shifts a day may require rebuilding in as little as 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, which are replaced and lubricated as one of the first steps in the rebuilding process. 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 undergoes way grinding to ensure proper alignment and even surface contact. After way grinding, the bed is refinished and painted. Material is then removed from the bottom of the saddle, and bonding material is applied to raise the saddle to its intended position. The saddle is hand scraped to achieve the factory-specified height, aligning it correctly with the feed shafts and lead screw as they pass through the apron. The saddle is placed on the bed and moved back and forth multiple times to identify and address high spots, ensuring proper contact with the bed.
The final phase of lathe rebuilding involves rigorous testing. A standard test includes cutting a workpiece using a 3-jaw chuck. To pass this test, the rebuilt lathe must achieve a tolerance of 0.0001 inches per inch over a 4-inch cut and produce a satisfactory surface finish.
The examples of machine rebuilding provided here represent just a fraction of the types of machines that can be restored to like-new condition. While machine rebuilders have the capability to refurbish virtually any type of equipment, many specialize in specific kinds of machines. These specialists possess the parts, experience, and expertise needed to restore their particular machines to their original factory specifications.
Mazak USA manufactures cutting-edge machines capable of performing a broad spectrum of machining tasks. The high precision of Mazak USA equipment ensures that even the tightest tolerances can be achieved with great ease and accuracy. With a PCL interface and hybrid engineering, Mazak USA machines deliver superior performance and eliminate the need for additional processing steps.
The Integrex i-400ST AG is a versatile multi-tasking machine designed for optimal throughput. It integrates high-powered turning and comprehensive machining functions to complete parts in a single setup. Featuring a second turning spindle and lower turret, the Integrex i-400ST AG minimizes the need for fixtures, tools, handling, and non-cut time. Its technological advancements significantly reduce lead times and enhance accuracy, eliminating the need for multiple production and machining stages.
The Mazak Integrex e-500H Multi-Tasking Machining Center performs turning, milling, boring, and drilling within one machine setup, delivering outstanding accuracy. This machining center is capable of handling heavy components, large diameter parts, and shaft-type workpieces across various industrial applications. It features a high-output spindle motor with dual gear ranges for heavy-duty machining, along with a drop worm system for precise positioning. The machine includes a 50 taper single turret with an automatic tool changer and a robust cam on the B axis for enhanced tool flexibility.
The Variaxis i-1050 offers 5-axis machining for processing large, detailed, and complex parts in a single setup. Unlike other CNC machines, the Variaxis i-1050 excels in machining workpieces with very thin surfaces while maintaining exceptional accuracy and tolerance. It is equipped with a 50 taper milling spindle, available in standard, high-speed, and high-torque versions. The trunnion unit supports a rigid tilting rotary table on both ends, ensuring that milling operations are not obstructed. The machine’s high-speed capabilities are attributed 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 optimized for machining large, low to medium-profile, challenging workpieces, particularly those made from heavy metals like stainless steel, titanium, and other alloys. Its efficient design enhances throughput, reduces machining time, and boosts profitability.
Repairing a Mazak machine tool, such as a Mazak Computer Numerical Control (CNC) machine, is a specialized task requiring the skills of a trained technician or engineer. Expertise is crucial to ensuring the machine’s safety, functionality, and durability.
Lack of Knowledge and Experience: If you lack experience or proper training with Mazak equipment, it is advisable to leave repairs to qualified professionals. Attempting repairs without the right expertise can cause additional damage and pose safety risks.
Complex or Critical Components: Mazak machines often contain complex and critical components like CNC controls, spindle systems, and precision ball screws. Repairing or calibrating these parts demands specialized knowledge and equipment.
Safety Concerns: If you face safety issues such as electrical malfunctions, coolant leaks, or structural problems, it is crucial to seek professional assistance immediately. Ensuring safety should always be the highest priority.
Warranty and Service Contracts: Attempting DIY repairs on a Mazak machine under warranty or a service contract might void these agreements. Repairs should be performed by authorized professionals to keep warranties and service contracts valid.
Diagnostic Challenges: If you cannot accurately identify the problem or error with the machine, it is a clear indication to consult a professional technician. They possess the tools and expertise needed for thorough diagnostics.
Availability of Spare Parts: When repairs require replacement parts that are not readily available or accessible, it is best to rely on professionals who have access to Mazak's authorized parts suppliers.
Specialized Tools and Equipment: Many Mazak repairs necessitate specialized tools and equipment for tasks such as disassembly, calibration, and testing. Professionals are equipped with these tools and are trained to use them effectively.
Minimizing Downtime: Professional technicians can often diagnose and repair issues more quickly, reducing operational downtime. This efficiency is crucial for businesses that depend on Mazak machines for production.
Manufacturer Expertise: Authorized service technicians from Mazak have extensive knowledge of Mazak machines, including the latest models and updates. They provide the most accurate and up-to-date support.
Legal and Liability Concerns: If you attempt repairs yourself and inadvertently cause damage or safety issues, you may be held liable for the consequences. Professional technicians carry insurance and certifications to protect both you and your equipment.
Preventive Maintenance: In addition to repairs, professional technicians can perform preventive maintenance to ensure your Mazak machine remains in optimal condition and to reduce the risk of future breakdowns.
Working on intricate machinery like Mazak machines requires specialized knowledge. If you do not have the required expertise, tools, or access to authorized parts, seeking professional help is generally the best course of action. This approach ensures safety, maintains the integrity of the machine, and preserves warranty or service contract coverage.
Often, there is confusion about the distinctions between retrofitting, rebuilding, and remanufacturing. While these terms are frequently used interchangeably, they refer to different processes and outcomes. Understanding the differences between these terms is crucial as they define how a machine will be modified or upgraded after undergoing these processes.
Retrofitting involves upgrading a machine’s tool control system by replacing components such as drives, axis motors, and spindle motors. This process is typically carried out at the customer’s location. It focuses on enhancing an existing older machine by incorporating new features and updating its capabilities. The update often includes integrating automation to allow older machines to fit into contemporary production methods.
Advantages of remanufacturing:
Rebuilding encompasses a comprehensive range of processes aimed at restoring and replacing various components of a machine to make it look and function like new. This process involves numerous improvements, from major systems to simple parts such as switches, hoses, bolts, and belts. The objective of rebuilding is to return the machine to its original condition based on its design specifications. Rebuilders rely on the original manufacturer's diagrams, provisions, and guidelines to restore the machine to full operational efficiency.
Advantages of remanufacturing:
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 offers a cost-effective option compared to buying new machines. This process involves upgrading outdated and older equipment to incorporate the latest technology, effectively transforming them into modern, high-tech machines.
Advantages of remanufacturing:
Wear and tear on production machines can lead to complex issues that require resolution by skilled technicians and engineers. Astro Machine Works possesses the talent and expertise needed to tackle any machine repair or rebuild. The company reverse engineers components to meet manufacturer specifications efficiently and cost-effectively. They provide a clear outline of each step in the rebuilding process to restore semi-functional machines to their original manufacturer’s standards.
Machine Rebuilders specializes in over 130 different types of machines, including lathes and milling machines. As an authorized dealer for Centroid and FANUC CNC controllers, they are experts in rebuilding CNC machines and integrated systems. Their team includes engineers, electricians, mechanics, CNC control technicians, and researchers, all committed to offering the best solutions for industrial machine issues. Rebuilding services are available both on-site and at their New Derry, PA facility.
Precision Service is dedicated to restoring machines to their original functionality by cleaning, repairing, and replacing critical components. Their experienced technicians rejuvenate outdated equipment, transforming it into essential machinery for production. The company focuses on extending the lifespan of machines through meticulous attention to detail during the rebuilding process. Precision Service specializes in CNC lathes, turret lathes, toolroom lathes, and grinders, and has the expertise to maximize machine performance.
KRC offers comprehensive tool overhauls to return machines to their original specifications. They clean, inspect, and rebuild every aspect of a machine using both re-machined and new parts. KRC assists with rebuilding boring mills, gantries, and bridge mills, and is equipped to handle mechanical and CNC control issues. The company supports 16 popular machine brands, including Toshiba, Mario Carnaghi, and SNK.
WIMS excels in machining, CNC operations and programming, and various repair services. Their success is attributed to the strong working relationships they maintain with clients. These relationships contribute to the high performance of their rebuilt equipment. Using top-quality tools and processes, WIMS ensures that all machines meet the performance standards expected of new equipment. Each machine undergoes a thorough examination and evaluation to guarantee a flawless rebuilding process.
Machine rebuilding offers a way to update outdated equipment. When machinery demands frequent repairs and leads to significant downtime, the usual response might be to replace it with new equipment. While this might seem like a straightforward solution, there are more cost-effective alternatives that can enhance the use of existing resources.
Rebuilding machines is a proactive and effective approach to refurbishing outdated equipment by incorporating modern technological features. With the high costs associated with purchasing new machinery, rebuilding presents a more affordable option, typically costing around 75% of a new machine. This method also helps avoid the challenges of disposing of old equipment.
The success of an industrial operation largely hinges on managing fixed costs, with equipment being one of the most significant expenses. Repairs, upgrades, and downtime can consume a substantial portion of a manufacturer’s budget. Effectively managing these costs is crucial for maintaining profitability in manufacturing operations.
Equipment that has been in regular use for 15 years often appears outdated and worn, which might lead to the consideration of replacement. However, machine rebuilding provides a cost-effective alternative to buying new machinery. While the rebuilding process is intricate and time-consuming, it can modernize equipment that is 10 to 15 years old at roughly 75% of the cost of new equipment. This approach not only enhances the performance and aesthetics of the machinery but also extends its lifespan.
In the machine rebuilding process, rebuilt machines undergo a more rigorous inspection compared to new ones. Every component, including bolts, screws, and parts, is thoroughly examined for functionality and performance. Parts that are damaged or excessively worn are replaced with new ones, while those that remain in good condition are cleaned and refurbished.
This meticulous inspection process is a key factor that machine rebuilders use to showcase the quality of their work. Unlike machine manufacturers who often assemble machines with new parts but with minimal inspection of individual components, rebuilt machines are carefully evaluated, with performance being assessed through detailed checks rather than just pre-shipment testing.
The rapid pace of technological advancement in the 21st century has introduced numerous improvements in equipment and control systems that were not available a decade ago. Many industrial processes now rely on electronic controls, which have rendered older equipment less competitive. However, machine rebuilding can transform outdated machinery into modern, efficient equipment.
During the rebuilding process, older equipment can be updated with new technologies. For instance, old presses, lathes, and mills can be fitted with modern controllers, CNC coding, and PLC programming. Rebuilders possess the expertise and tools needed to convert a worn-out press into a state-of-the-art CNC-operated machine.
Rebuilding and updating old equipment contributes to sustainability by preventing the disposal of machines that still have functional value. While old equipment may not be discarded, it often ends up stored away as unused waste. Embracing sustainability involves making the most of existing resources, and machine rebuilding plays a crucial role in this effort by transforming outdated equipment into new, functional machinery.
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