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Simple repair method for larger diameter bending shaft
In the course of operating machinery like mixers and crushers within the Construction Materials sector, it’s quite common for spindles to become deformed or bent due to the presence of metal fragments or other debris. Once a spindle is bent, it can be challenging to fix it without resorting to expensive repairs or scrapping the entire component. Through years of experience, I’ve developed a practical, hands-on approach to manually straighten spindles with diameters greater than 90 mm. Here's how it works:
First, mount the spindle onto a lathe. Without starting the machine, use the tool holder to gently push the spindle back and forth along its length while rotating it manually to identify the exact point where the bend occurs. This step requires patience and attention to detail, as you’re essentially mapping out the curve of the deformation. A visual guide or diagram of the bending point will help ensure accuracy.
Once the bend is located, draw a circular outline around this area. The size of the circle should be adjusted based on the spindle's diameter—this will require some trial and error to get right. Next, using a small hammer, lightly tap the surface of the circle in a consistent, back-and-forth motion. The goal here is to apply enough force to slightly expand the metal at the bent section, allowing it to straighten out over time. Be sure to distribute the taps evenly to avoid creating new distortions.
After approximately 30 minutes of tapping, remove the spindle from the lathe and inspect the results. It may take another round of testing on the lathe to assess how much improvement has been achieved. Based on my experience, for a spindle with a 100 mm diameter, the entire process usually takes around 100 minutes of tapping to achieve noticeable straightening.
This technique is straightforward and efficient, but it does have limitations. For spindles with diameters smaller than 90 mm, this method tends to be less effective. Smaller spindles often suffer from more severe bending issues, which can be harder to resolve through manual correction alone.
While this solution offers a cost-effective alternative to replacing damaged spindles, it’s important to note that careful calibration and steady application are key to success. If done improperly, there’s a risk of further damaging the spindle or introducing new bends. With practice, however, this method can save both time and resources in industries reliant on heavy machinery.