Introducing new machine tools in this competitive market is a significant challenge for OEMs. A machine tool must balance costs and features to meet customer demands while supporting profitability. CNC spindles are critical components of machining centers, and OEMs have various choices to make during spindle selection. By examining these choices, you can determine when it’s valuable to work with a third-party supplier or if you should keep spindle engineering, designing, and building in-house.
As machining needs and technology have evolved, OEMs have multiple options, including customized spindles, to suit various machining needs and applications. Selecting the right drive system is critical to maximize machine performance for end users. Some of the main spindle drive systems include:
Choosing the right CNC spindle requires careful consideration of several factors. Different spindle types will serve different end users, so understanding your audience and their machine tool requirements can help you choose the right spindle for your latest model. Factors include:
Torque is a force that acts perpendicular to the axis of rotation for a given radius from that axis. The torque is how hard the drive can push the cutting edge of a tool into the material being cut. Horsepower refers to how quickly torque can be applied.
Finding the right balance between torque and speed is essential. High-speed spindles are ideal for applications requiring smooth finishes and complex details. Spindles with higher torque often operate at lower speeds but provide the necessary force to machine rigid materials like steel or titanium.
The required level of accuracy and precision depends on the machining application. For example, aerospace or medical applications require manufacturing with high repeatability and extremely tight tolerances. These applications demand spindles with low runout, low vibration characteristics, high-quality bearings, and a rigid design. Consider the audience and intended purpose of your latest machine tool to determine the right spindle design.
A spindle’s cooling method is crucial to its performance and longevity. Two principal cooling systems exist:
A CNC spindle’s life span impacts profitability and efficiency for end users. By extension, a long-lasting spindle can lead to higher customer satisfaction and a strong brand reputation. Maximizing spindle longevity involves considering several factors, including operational frequency, load conditions, and maintenance practices. Factor in the expected use cases of your machine tool to determine the type of wear a spindle will experience. When selling to end users, it’s important to communicate maintenance requirements through operator’s manuals to support tool longevity.
Choosing an experienced, reputable supplier is essential for designing your machines with high-quality spindles. Look for a supplier with a consistent record of providing exceptional customer service, meeting delivery times, and supplying long-lasting, high-performing parts at competitive prices. See if the supplier has ISO 9001 certification to ensure they’re committed to quality and meeting customer expectations.
At Setco, we’ll gather your data and establish performance criteria like speed, torque, power, precision, stiffness, and thermal stability. The operating environment must also be considered, including temperature, humidity, and potential contamination. From there, we define the interface with the machine tool, including mounting, drive system, and tool holder compatibility. With these parameters in mind, we can design a spindle that elevates the quality of your machined components, productivity, and cost savings.
Many OEM applications require a custom design. In these cases, we use over a century of experience to generate multiple design concepts, which we review in detail with our clients, creating a cooperative and collaborative environment. Pricing is generated using historical costs from similar parts and assemblies. Once our customers approve, we move to the design stage. We confirm all the calculations to analyze stresses, deformations, and thermal and centripetal effects under various operating conditions.
Our design engineers develop computer-aided design (CAD) models of the spindle components, including the shaft, bearing, housing, seals, motor windings, encoders, and additional sensors. Parts are detailed and undergo multiple rounds of comprehensive evaluation by different engineers, providing a fresh perspective and expert review in each design stage. This process ensures that our team catches all the small details and increases OEMs’ competitive advantage.
We implement rigorous quality assurance procedures to ensure consistent production of high-quality spindles. We have ISO 9001:2015 certification and hold our precision parts to the most rigorous quality standards. We manufacture and assemble each spindle with micron-level precision to ensure its durability and reliability under maximum operating speeds. Once a spindle has passed all testing and quality requirements, the Setco Goldline report will be generated outlining this data. We add the final touches, such as paint and packaging, before shipping units to OEMs.
As a major spindle manufacturer with over 325,000 new and rebuilt spindles in the field, Setco is a trusted source for spindle design, manufacturing, and repair worldwide. We’ve been in business since 1912 and have amassed considerable expertise over the last century, providing OEMs with the skills and knowledge to maintain optimal performance in various manufacturing operations.
As an industry forerunner with 13 global locations, we have a strategy of continuous improvement and remain dedicated to manufacturing high-quality machine tool spindles and slides across industries. Our clients trust us to provide personalized attention to their business needs, regardless of location.
Choosing the best CNC spindle for your machine is a crucial decision that affects machine tool quality, customer satisfaction, and profitability. Factors such as material compatibility, speed, power, and torque can help you make an informed decision that provides the required CNC machining performance. Investing in a high-quality spindle tailored to your machine tool’s applications will equip it to deliver the best possible output.
As the world’s largest independent spindle rebuilder, Setco has been a leader in the spindle industry for decades. Leverage our vast experience and work with us to create the best solution for your application. We also specialize in servicing and repairing CNC machine tools from over 350 brands, offering the after-sales support customers need to maintain productivity and reduce downtime. Contact us to learn more about our wide range of spindle options and make the best choice for your application today!