Preventative Maintenance for Live Tools – Stop Catastrophic Failures Before They Happen
Live tools are essential in modern CNC machining. They allow for increased versatility, reduced setup times, and tighter tolerances in high-speed production environments. But like any precision instrument, live tools are only as reliable as their maintenance routine. Unfortunately, many manufacturers wait until there’s a noticeable problem before servicing their tools. By then, it’s often too late.
The Hidden Cost of Neglecting Your Tools
Internal components such as bearings, seals, and gear mechanisms are subject to tremendous stress during operation. Without regular inspections and lubrication, these components wear down faster than expected. Over time, small imbalances or heat-related damage can turn into major issues such as seizing tools, broken spindles, or even full equipment failure. The result? Unplanned downtime, emergency replacements, and production delays that can cost thousands.
Regular preventative maintenance gives you the power to stop these failures before they happen.
Real-World Case Study: Thousands Saved with Routine Care
One of our long-term clients, a mid-sized aerospace parts manufacturer in the Midwest, approached us after suffering two expensive tool failures within six months. After analyzing their tool usage and production volume, we proposed a quarterly preventative maintenance schedule focused on inspecting bearings, replacing seals, and recalibrating tool alignment.
Within the first cycle, our machinists detected early signs of bearing fatigue on three live tools. Had the customer waited until symptoms appeared, each of those tools could have failed during production. Instead, the customer paid for minor repairs and avoided over $25,000 in tool replacements and production losses.
What Does Preventative Maintenance Include?
Our live tool maintenance process includes:
- Free evaluations on all incoming tools
- Thorough disassembly and internal inspection
- Bearings, seals, and other internal components replaced (as needed)
- Full inspection following repairs
- 50%-90% savings over the cost of a new tool
Proactive services ensure your tools operate at peak performance and give you peace of mind on the shop floor.
Standard PM Recommendations
Staying ahead of your preventative maintenance schedule helps protect you from costly investments and unexpected downstime. Recommendations for repair are based on the amount of time your tool is in use. With routine evaluations and replacements set in place from the start, CTS can save your live tools from catastrophic failure.
- Normal use, defined as running 1 to 2 shifts with incremental use = PM recommended annually
- Heavy duty use, defined as running 3 shifts, or constant use = PM recommended bi-annually
- Units with internal coolant capacity = PM recommended bi-annually
Can Carbide Tool Repair All Brands of Live Tools?
Yes! Carbide Tool Service’s has the ability to repair ALL types and brands of live tooling. Our U.S. based location saves you the time and money of shipping overseas in order to repair/replace your damaged tools. All live tools are restored back to complete OEM specifications.
Why risk catastrophic failure when routine maintenance can extend the lifespan of your tools, improve accuracy, and prevent lost revenue?
Contact Carbide Tool today to discuss a preventative maintenance plan customized to your operation. Let’s keep your shop running smoothly and avoid those high-cost surprises.