Hi everyone,

I'm reaching out to get some insight into a recurring issue we're having with an aggregate head on our CNC machine. It's a Techniks unit, and we're consistently running into problems after about 10 to 15 hours of use.

Here's what's happening:

After around 10–15 hours of runtime, the aggregate head starts making loud noises.

When we try to spin it by hand, there's noticeable resistance.

The unit runs continuously for about 1–2 hours at a time during normal operation.

It comes pre-filled with Castrol Alpha EP32 oil.

We've also noticed it gets quite hot during use.

We're wondering:

Is this expected behavior or are we doing something wrong?

Should we be using a different type of oil?

Could it be an issue with this particular brand or model of aggregate head?

Any guidance, experiences, or suggestions would be really appreciated. Thanks in advance for your help!

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Hi
You might be pushing the unit too hard, if it is heating up excessively you may be getting some thermal expansion of the gears inside causing the hard rotation.
How long does it sit between use? Is it getting adequate time to cool down?
I know it's an expensive unit but if it's a critical component to your manufacturing maybe you need 2 identical set ups, and you rotate them on and off to give it enough time to cool down between use.

Have you changed the oil in it yet? Usually they recommend the first oil change around 200 hours of use , then continue changing the oil every 500 hours.

I would talk to Justin Hurtubise at Techniks about this issue

Justin Hurtubise
Sales Rep - CNC Router Tools & Aggregate Heads
jhurtubise@techniksusa.com
1-317-417-8583
1-800-597-3921 ext. 1143
9930 East 56th St.
Indianapolis, IN 46236

Dan Povinelli
Connecticut Saw & Tool
www.ctsaw.com

Hi there and thanks for the response, and when we do run it we really do not give it time to cool off and for the oil, we run it for about 10hr total when we start to hear the unit failing.
i do suspect that it is also the heat that is cousing problems and i will be reaching out to Justin
thank you!

We have 4 Atemag aggregates on one 22 year old Benz. We use them sporadically and never for hard production. We have a dedicated horizontal spindle on our machine for constant production needs. Pricey, but more than worth it in the long run. All oif our aggregates are oil bath, which seem to last longer than the grease units while requireing no cool off periods. I recommend your next machine have a horizontal spindle for that work. Pays off big time.

Hi Mike, thanks for the reply we do notice that we use the aggregate pretty hard, and we are looking to get a new machine and hopefully it might be better in the meantime we might have to play around with feed rates and see how we can lower the wear and tear that the heat produces

Osvaldo,
One of the big advantages of a horizontal head is with a dedicated spindle you can run much bigger diameter heads to do the work. With more teeth and larger diameter, you can control your chip load and heat generated much better. Tools last longer, and the spindle doesn't work as hard. i typically run a 10" PCD V-groove saw for a year or more before service. occaisionally we swap out that head for a moulder that uses our standard HSS moulder knives for casing, crown, whatever needs cut on a radius. I'd have to do the KW calculations, but our unit is around 10hp.I'd prefer more, but it gets the job done.

Hi mike, thanks for all your input, about the horizontal head is the any brand/model that you may recommend? as well as aggregate tooling? we will also play around with the the chip load an monitor our tool better

I have only had two machines with a horizontal head. Both Northwoods. The first one was a moulder. That was a horizontal shaft supported on both ends. A little clunky to set up, but did a good job. Second one is a quick disconnect HSK 80. I can put standard saws, V-Groove saws, or moulder heads on it. It is supported on the one end with the prior mentioned HSK connection. I can change tool types, touch off and be running again in about 10 minutes. I really like that one. Northwood doesn't really have standard models. You just tell them what configuration(left/right, or front to back) and what tools you want to hang on the tool plate. If you get that far, you can reach out to me, I have some suggestions for adds that are must haves in my world.