HOMAG H6161H1269 HSK-F63 24 000 RPM

1. Reception and Registration

  1. The spindle is received either directly from the customer or via courier shipment.
  2. The order is registered in our system — including customer data, spindle model and serial number, taper type (HSK F63), maximum speed (24,000 RPM), and reported symptoms.
  3. An initial visual inspection is performed to check for external damage, overheating marks, contamination, or leaks.
  4. High-resolution “before” photos are taken and stored in the service file for documentation and comparison after repair.

2. Initial Diagnostics (Before Disassembly)

  1. The spindle is connected to a test bench and briefly run under no-load conditions.
    During this phase we record:
    • Sound and noise behavior (unusual vibration, knocking, whine),
    • Vibration levels,
    • Temperature rise (via infrared thermometer or thermal camera),
    • Electrical current and resistance readings.
  2. Electrical tests include:
    • Winding resistance and insulation measurement (megger test),
    • Current draw across different RPM levels,
    • Basic vibration analysis (axes X/Y/Z at several speeds).
  3. A preliminary diagnostic report is created with recommendations — e.g. bearing replacement, rewinding, cooling system repair.

3. Disassembly and Documentation

  1. Each component is carefully marked for reassembly alignment and orientation.
  2. External covers, toolholders, and cooling lines are removed.
  3. The spindle is extracted from its housing using lifting tools to prevent damage to taper surfaces or bearing seats.
  4. Each stage of disassembly is photographed and recorded, including part numbers and observations.

4. Cleaning and Surface Preparation

  1. Rough cleaning — removal of chips, dirt, and excess grease.
  2. Precision cleaning using ultrasonic baths or approved solvents, ensuring material compatibility (especially important for spindles with internal cooling circuits).
  3. Drying and surface inspection for scratches, wear, or corrosion.

5. Detailed Inspection and Measurement

  1. Geometrical checks:
    • Taper runout (radial and axial),
    • Concentricity and straightness of the shaft,
    • Bearing seat clearance and axial play.
  2. Non-destructive testing (NDT):
    • Magnetic or dye-penetrant inspection if cracks are suspected.
  3. Bearing analysis:
    • Condition of rolling elements, races, cages, signs of discoloration or overheating.
  4. Electrical inspection:
    • Winding insulation and resistance, lead condition, stator core inspection.
  5. Cooling system check:
    • Integrity of channels, seals, and connectors.

6. Service Decision and Cost Estimate

  1. Based on diagnostic results, a detailed quotation is prepared, listing all replacement parts and recommended operations.
  2. The customer reviews and approves the repair scope — we also offer “Basic” and “Premium” regeneration packages with different warranty terms.

7. Bearing Replacement and Mechanical Restoration

  1. Removal of old bearings using specialized tools and presses.
  2. Inspection and, if necessary, re-machining or regrinding of bearing seats to restore precision fits.
  3. Installation of new high-precision bearings (from top manufacturers) using controlled heating or pressing procedures.
  4. Replacement of seals, O-rings, spacers, and cooling components.
  5. Greasing or oil lubrication according to manufacturer recommendations and bearing specifications.

8. Electrical Rewinding and Component Repair (If Required)

  1. Rewinding of stator or rotor coils using high-grade materials and precise winding patterns.
  2. Replacement of internal cooling lines, thermistors, and connectors as needed.
  3. Post-repair electrical tests: resistance, insulation, and dielectric strength measurements.

9. Assembly and Preliminary Adjustment

  1. The spindle is reassembled following original markings and torque specifications.
  2. Bearing preload and axial clearances are set according to manufacturer tolerances.
  3. Rotational smoothness is checked manually before proceeding.

10. Dynamic Balancing

  1. The spindle undergoes both static and dynamic balancing using a precision balancing machine.
  2. Balancing is performed in one or multiple planes depending on design, reaching accuracy levels compliant with ISO G-class standards.
  3. All results are documented and attached to the final report.

11. Performance and Load Testing

  1. No-load testing: The spindle is run through its full speed range (up to 24,000 RPM) while monitoring:
    • Vibration levels,
    • Temperature rise,
    • Electrical parameters (current, voltage, phase balance).
  2. Load simulation: In certain cases, we apply a controlled load to simulate cutting forces.
  3. Thermal monitoring: Temperatures of bearings and windings are continuously recorded.
  4. FFT vibration analysis: Frequency spectrum is analyzed to identify harmonics or potential resonance.
  5. Tool interface repeatability test: Ensures precise taper positioning and clamping consistency.

12. Final Quality Control

  1. Comparison of all key parameters with manufacturer specifications.
  2. Final measurements of runout, vibration, current, and temperature.
  3. Preparation of complete measurement documentation: before/after results, charts, and photos.
  4. Issuing a FUMAK Quality Certificate and detailed service report.

13. Packing and Shipping

  1. All critical surfaces (taper, shaft ends) are protected with covers and anti-corrosion films.
  2. The spindle is packed in a secure wooden crate or reinforced carton with anti-shock filling.
  3. Documentation included:
    • Service report,
    • Measurement certificates,
    • Warranty card,
    • Handling instructions.
  4. Shipment is arranged by FUMAK or the customer’s logistics partner.

14. Warranty and After-Sales Support

  1. All FUMAK spindle regenerations include a written warranty covering both labor and parts.
  2. Post-service support:
    • Technical consultation via phone or online,
    • On-site inspection (if needed),
    • Preventive maintenance recommendations.
  3. Customers receive suggestions for maintenance intervals and condition monitoring best practices.

15. Optional Services

  • Cooling system modernization or additional temperature sensors.
  • Foto report of the entire repair process.

16. How to Prepare a Spindle for Shipment

  1. Disconnect the machine from power.
  2. Secure the tool taper to prevent movement.
  3. Clean external surfaces of coolant and chips.
  4. Pack the spindle securely in a padded box or crate.
  5. Include a note describing symptoms, visible damage, and contact details.
  6. Contact FUMAK before shipping — we will provide full transport instructions.

17. FAQ — Common Customer Questions

Do you only replace bearings?
Not necessarily — bearing replacement is just one step in a complete regeneration process. The full scope is determined after diagnostic testing.

Will the spindle perform like new?
Our goal is to restore the spindle’s precision and performance to factory-level parameters within allowable tolerances. In some cases, if major damage is found, certain components may be replaced entirely.

Do I receive a report?
Yes — each spindle repair comes with a detailed before and after report including measurements, vibration graphs, and high-resolution photos.

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