Worn leadscrew?

[JAZZCNC]

i am using 15mm tbi motion linear rails on the gantry. I have changed my setup 6 months ago, moved leadscrew too high above the linear rails. I am always pushing my machine to the limits of the spindle (3000mm/min, 2mm wall, 15mm deep, 10mm endmill). I think this was the cause to wear them. I didnt have any issue before the change.

I am changing gantry rails now with 25mm, and putting leadscrew between the linear rails. Considering buying 6.6kw hsk63 spindle.

TBI are decent enough linear rails and I still wouldn't expect them to wear out like this, also those cutting parameters while at the limit of the spindle shouldn't be anywhere near affecting the linear rails.
If the machine cannot handle 2.2Kw or 3Kw spindle then it certainly won't handle a 6.6Kw HSK63 spindle and just fitting larger rails may not be enough. I would look carefully at the machine to see if can find any other cause for the rails wearing out in that manner because I'm pretty sure it's not just because you have moved the ball-screw position. That large spindle will quickly find any weak areas and you could be back to square one chasing issues.

[m_c]

TBI are decent enough linear rails and I still wouldn't expect them to wear out like this, also those cutting parameters while at the limit of the spindle shouldn't be anywhere near affecting the linear rails.
If the machine cannot handle 2.2Kw or 3Kw spindle then it certainly won't handle a 6.6Kw HSK63 spindle and just fitting larger rails may not be enough. I would look carefully at the machine to see if can find any other cause for the rails wearing out in that manner because I'm pretty sure it's not just because you have moved the ball-screw position. That large spindle will quickly find any weak areas and you could be back to square one chasing issues.

If the machine is using this design - http://www.mycncuk.com/threads/10118...2769#post82769 I'd say it'll be putting quite a lot of leverage on the rails through cutting forces.
Looking at the diagrams, it must be verging on a 2:1 leverage between the lower trucks and the upper trucks, which I'd guess will be pushing 15mm rail to their limits.
However I'd probably look at doubling up the 15mm rails, rather upsizing given the design.

[JAZZCNC]

If the machine is using this design - http://www.mycncuk.com/threads/10118...2769#post82769 I'd say it'll be putting quite a lot of leverage on the rails through cutting forces.
Looking at the diagrams, it must be verging on a 2:1 leverage between the lower trucks and the upper trucks, which I'd guess will be pushing 15mm rail to their limits.
However I'd probably look at doubling up the 15mm rails, rather upsizing given the design.

If I remember right there are 3 rails on this Y-axis design with 2 bearings on each rail so I wouldn't expect them to wear out the rails in just over 3yrs. Even the bearings should last that long and they would wear long before the rails.? . . . But you could be right because the Z-axis is a long lever.?.

Matt which rail is worn out and how many does it use.? . . . Also how many hours does the machine have on it.? (mach3 will tell total operating time)