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Abstract:
This video documents the process of diagnosing and repairing significant runout on the cutter arbor of a MOAC machine. Initial checks with a dial indicator reveal the cutter plate itself is straight, isolating the problem to the arbor. The arbor is removed and meticulously re-machined in a lathe, first truing the mounting face and then re-cutting the taper to improve concentricity. Post-machining checks confirm a substantial reduction in runout. Subsequent test cuts on steel plate demonstrate a significant improvement in the machine's roughing capability, achieving double the previous feed rate. However, achieving a perfect finishing cut proves challenging due to minor variations in insert height, indicating a limitation separate from the now-corrected arbor runout. The repair is ultimately deemed successful, greatly enhancing the machine's performance.
Troubleshooting and Repairing MOAC Cutter Arbor Runout
0:00:30 Initial Problem: The MOAC machine's cutter has significant runout, requiring investigation and repair.
0:00:43 Initial Diagnosis - Cutter Plate: The cutter plate is removed from the arbor and checked for straightness using a dial indicator.
0:02:41 Cutter Plate Result: The cutter plate is found to be surprisingly straight (minimal runout, ~0.01mm), indicating the plate is not the source of the problem.
Key Takeaway: The issue lies deeper, likely within the arbor or spindle.
0:03:40 Diagnosis - Arbor Runout: The arbor is checked without the cutter plate attached, confirming significant runout originating from the arbor itself.
0:04:13 Repair Strategy: The plan is to remove the arbor, clean it thoroughly, and re-machine its critical surfaces in a lathe to restore concentricity.
0:06:44 Lathe Setup: Precision setup of the lathe's compound slide is performed using a dial indicator to ensure accurate machining of the arbor taper.
0:09:49 Arbor Machining - Face: The arbor is mounted in the lathe, and the face where the cutter bolts on is machined true.
0:18:06 Face Runout Check: The machined face now runs perfectly true.
0:18:18 Arbor Machining - Taper: The runout on the arbor's taper is measured (0.08mm) and then the taper is re-cut in the lathe. Cutting fluid is used for a better finish on the final pass.
0:21:25 Post-Machining Check: The arbor is reinstalled in the MOAC, and runout is measured again.
0:24:08 Runout Result: Runout is significantly reduced to 0.01mm on the arbor, translating to an acceptable ~0.03mm at the cutter's outer diameter.
Key Takeaway: Re-machining the arbor successfully addressed the primary runout issue.
0:25:33 Test Cut Setup: The machine is reassembled, and a test cut is prepared on a piece of 350-grade steel plate, starting at 63 RPM and 5mm/min feed rate.
0:26:39 Roughing Test & Optimization: Feed rate is progressively increased (up to 36mm/min), followed by RPM increases (to 73, 88, aiming for ~100 RPM) to find optimal roughing parameters.
Key Takeaway: The machine can now handle roughly double the previous feed rate (36mm/min) at ~100 RPM with a 1mm depth of cut, significantly speeding up jobs.
0:32:09 Finishing Test: A finishing cut (0.2mm depth, lower feed) is attempted to assess surface quality.
0:32:55 Finishing Result: The finish is decent, but only one or two inserts are engaging, indicating variations in insert height rather than arbor runout are now the limiting factor for perfect finishing.
0:35:04 Final Assessment: The arbor repair successfully eliminated the major runout problem and doubled the machine's roughing performance. Achieving a perfect finish would require addressing insert height consistency, possibly by manual grinding/shimming. Overall, the project is considered a success.