MACHINE REBUILDING SERVICES
Machine Rebuilding Services
At Blue Diamond Machine Tools, we offer comprehensive machine rebuilding services for your machines during maintenance. These services include everything from partial overhauls to complete rebuilds or re-engineering to CNC. We also upgrade existing machine tools with the latest control technology and electronics, revitalising your current hardware to enhance performance.
Refurbishing machine tools has many benefits and our machine rebuilding services can help. It is a cost-effective solution compared to buying new equipment, making it ideal for those with limited budgets. machine rebuilding services restores machine productivity, enhancing performance and capacity without the high expense of new machines. Additionally, it leads to reduced downtime, scrap and maintenance costs, ensuring that production processes remain efficient and economical. Ignoring necessary repairs can cause significant damage and escalate costs, but machine rebuilding services, refurbishment and regular maintenance mitigates these risks.
At Blue Diamond Machine Tools we pride ourselves on our ability to offer machine rebuilding services and refurbishment services for almost any type of machine, including grinders, lathes, friction welders, mills, saws, slotters and more. Once the machine rebuilding services or refurbishment is complete, each machine undergoes meticulous alignment checks to ensure it meets the highest standards and fulfils customer requirements.
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- The machine was fully stripped down in its entirety right back to bare castings
- The Bed, saddle cross slide and compound slide where all reground to BS 4656 Part 2
- The saddle had a linear bearing material screwed and bonded to it, then scrape in and gibbed up
- All the other slides where scraped in and re-aligned correctly
- All the gearboxes had New bearings and Seals fitted right throughout including new spindle bearings
- The gearboxes where fully rebuilt ready for refitting
- All the leadscrews and nuts where replaced with new as well as a new feeds shaft
- The casting flatted off and primed ready for painting
- The machine was painted to high standard in standard or corporate colours
- The machine had complete new electrical panel with new equipment all round and 3 copies of new drawings
- The machine built back up and test cuts taken to prove the accuracy and alignments of the machine
- The machine rebuilding services were complete
- The machine is stripped into its various components cleaned and visually inspected ready for a report. A report is generated on all our refurbished machines and a copy sent to the client for any extra work require or parts being highlighted.
- This is then carried out within the refurbishment when the client has sanctioned the parts and work required over and above the scope of work within the original quotation. The parts are painted when they are off the machine as and when required.
- Then the machine bed has its gap piece scraped in if applicable and then set up on our 6 metre slideway grinder with a horizontal and vertical spindle so all grinding is peripherally ground for greater accuracy and a better surface finish.
- We can grind 6 x 1 x 1 meter’s on this machine and the machine is checked every year with a laser for accuracy and all work required on the machine is carried out by us. We have just fitted new slideway covers and 2 off vertical lead screws and nuts to the machine to improve its performance and accuracy.
- The machine bed usually has between 0.15 and 0.5 mm ground from each face but we have been known to grind as much as 1.6 mm from some slides to get them true again. Then on completion of that the base is then painted ready to be worked on.
- Then the machine is set up and levelled on floor plates to allow the saddle and cross slide to be scraped in after having a linear bearing material screwed and bonded to the saddle and cross slide if required. The saddle is scraped in and checked with a DTI and square to maintain the correct alignment both underneath saddle and the squareness to the bed to maintain headstock to turn flat across its face.
- The oil galleries are then cut into the new linear bearing material and the lube system checked, prior to the gib strips being gibbed up and keep plates fitted as required. Fit new slide wipers to the saddle and cross slide if applicable. Scrape the tailstock base into the bed section and re align in both plains ready to set the centre height of the tailstock after the headstock has been realigned.
- The machine is built up after the gearboxes are visually checked and serviced if required the headstock and tailstock are aligned correctly as we take test cuts on the headstock then align the tailstock to suit.
- Having being fully painted during this whole process the machine is now ready for inspection by the client and the relevant inspection sheet is completed for pass off by the client. We also welcome any impromptu visit by the client during the scope of work and all parts replaced can be sent back with the machine if the client would like them returning.
- The machine rebuilding services were complete
- The machine was removed from its cell to allow the following work to be carried out unfortunately the client would not allow any more than 1 photo to be used and none to be taken on site at their request.
- The machine was fully stripped down as required and a full report given to the client of the machines faults and broken / damaged parts
- The slides where removed and reground and set back up on the base of the machine as required
- The headstock was fully stripped down and new spindle bearings fitted
- The front side plate was replaced with a new one as the old had a stress fracture running through part of it
- All the hydraulics and electrics were fully overhauled and rams being checked and resealed as required.
- The machine mechanisms fully overhauled and the job carriage and work holding equipment overhauled and then refitted and aligned with the headstock.
- The machine and parts were painted during all the processes ready for rebuild
- The machine was assembled complete ready to be delivered back to the client and then put back in the cell and hydraulics and electrics re connected and all safety gates and windows interlocked ready for test cuts. Test cuts taken on site and the machine passed off ready for use again
- The machine rebuilding services were complete
- The machine is stripped into its various components cleaned and visually inspected ready for a report. A report is generated on all our refurbished machines and a copy sent to the client for any extra work require or parts being highlighted.
- This is then carried out within the refurbishment when the client has sanctioned the parts and work required over and above the scope of work within the original quotation. The parts are painted when they are off the machine as and when required.
- Then the machine bed is set up on our 6 meter slide-way grinder with a horizontal and vertical spindle so all grinding is peripherally ground for greater accuracy and a better surface finish. We can grind 6 x 1 x 1 meters on this machine and the machine is checked every year with a laser for accuracy and all work required on the machine is carried out by us. Then on completion of that the base is then painted ready to be worked on.
- Then the machine is set up and leveled on floor plates to allow the table and wheel-head slides to be scraped in The table is scraped in and checked with a DTI and level to maintain the correct alignment in both plains.
- The bed’s the oil galleries are then re cut if required lube system checked prior to the bed being refitted for good. The wheel head slides are both ground and scraped as required and fitted back to the base and realigned in all 3 axis. Then grind and scrape the swivel top table as required ready for the work-head and tailstock.
- The machine is built up after the gearboxes are overhauled and serviced as required all leadscrew’s and nuts changed and hoses and piper work repaired / replaced as required. All mechanical mechanisms fully serviced ready for use the lubrication system flushed through and repaired as required then the oil restrictors set as required to allow the correct amount of oil to lubricate the slides and we tend to have more than less to keep the machines life and functioning to a higher level. The tailstock base is scraped into the bed section and aligned on all axes true with the morse taper.
- The workhead base is then scraped into the swivel table and swivel between the two faces of the workhead re scraped. Then this is aligned with the tailstock correctly as we take test cuts on the machine after setting the workhead and tailstock with a precision test bar between centers.
- Having being fully painted during this whole process the machine is now ready for inspection by the client and the relevant inspection sheet is completed for pass off by the client. We also welcome any impromptu visit by the client during the scope of work and all parts replace can be sent back with the machine if the client would like them returning .
- The machine rebuilding services were complete
To include all NEW Electrics and New Fanuc control, drives and spindle & axis servo motors.
All the PLC ladders were written In-House. All slides fully reground, then mechanically overhauled as well as the ballscrews and nuts reworked and realigned.
The turret mechanism was repaired as required and the machine was then rebuilt to manufactures specification and alignments.
The machine was then laser aligned prior pass off by the client, making the machine rebuilding services complete.
Slideway Grinding – Machine Rebuilding Services
Slideway Grinding is part of our machine rebuilding services. The machine bed has its gap piece scraped in if applicable and then set up on our 6 metre slide-way grinder with a horizontal and vertical spindle so all grinding is peripherally ground for greater accuracy and a better surface finish.
We can grind 6 x 1 x 1 metre’s on this machine and the machine is checked every year with a laser for accuracy and all work required on the machine is carried out by us. We have just fitted new slide-way covers and 2 off vertical lead screws and nuts to the machine, to maintain the machines performance and accuracy.
The machine bed usually has between 0.15 and 0.5 mm ground from each face but we have been known to grind as much as 1.6 mm from some slides to get them true again. Then on completion of that the base is then painted ready to be worked on.
