Experimental and simulation study on the thermal characteristics of the high-speed spindle system

2016 ◽  
Vol 231 (6) ◽  
pp. 1072-1093 ◽  
Author(s):  
Chi Ma ◽  
Liang Zhao ◽  
Hu Shi ◽  
Xuesong Mei ◽  
Jun Yang
Keyword(s):  
Temperature Field ◽  
High Speed ◽  
Thermal Structure ◽  
Fractal Theory ◽  
Thermal Contact ◽  
Thermal Characteristic ◽  
Machining Accuracy ◽  
Heat Power ◽  
Spindle System ◽  
Fea Model

High-speed spindles often suffer from degeneration in its machining accuracy caused by the uneven distribution of temperature field. In order to improve the machining accuracy of high-speed spindles, a three-dimensional (3D) finite element analysis (FEA) model, which considered the combined effect of thermal contact resistance (TCR) and the change in heat power and stiffness caused by thermal displacements of bearing components on the accuracy of simulation results, was proposed to conduct transient thermal-structure analysis of high-speed spindles. The predictive model for TCR was proposed based on the fractal theory to characterize the rough surface morphology with disorder, self-affinity and non-stationary random features. And a contact mechanics model was developed to consider the influence of asperities’ deformation on TCR. The thermal-structure model of bearing was proposed to calculate the heat power and stiffness based on the quasi-static mechanics analysis. The FEA model proposed in this paper was used to simulate the temperature field distribution and thermal deformations of the high-speed spindle system. Then thermal characteristic experiments were conducted to validate the effectiveness of this model. The results showed that the FEA model was much more accurate than the traditional model which ignored the above two important factors. The temperature field and thermal errors of the spindle system were analyzed.

scholarly journals An Improved Thermal Performance Modeling for High-speed Spindle of Machine Tool Based on Thermal Contact Resistance Analysis

2021 ◽  
Author(s):  
Bing Fang ◽  
Mengna Cheng ◽  
Tianqi Gu ◽  
Dapeng Ye
Keyword(s):  
Temperature Field ◽  
Temperature Distribution ◽  
Thermal Resistance ◽  
Thermal Performance ◽  
High Speed ◽  
Thermal Contact ◽  
Great Influence ◽  
Contact Thermal Resistance ◽  
Spindle System ◽  
Fea Model

Abstract The distribution of the temperature field has a great influence on structural performance, thermal deformation, thermal error compensation. To improve the prediction accuracy of the temperature distribution of the spindle system, a comprehensive model considering the contact thermal resistance (TCR) of the interfaces was established to analyze the thermal performance of high-speed spindle system in the present work. An elastoplastic contact model was used to calculate the contacting areas and loads of interfaces, which were employed to establish the contact thermal resistance model of the main interfaces of spindle, such as bearing rings and tool holders. Basing on the TCR parameters, a Finite Element Analysis (FEA) model was proposed to analyze the temperature distribution of the spindle system. And a temperature test experiment was set up to verify the accuracy of the FEA model. The results show that the relative error of representative test points was all less than 5%, which means the established model can appropriately reflect the temperature field distribution of the spindle.

Stiffness optimization for high-speed double-locking toolholder-spindle joint using fractal theory

2017 ◽  
Vol 232 (4) ◽  
pp. 418-426
Author(s):  
Zhifeng Liu ◽  
Jingjing Xu ◽  
Yongsheng Zhao ◽  
Qiang Cheng ◽  
Ligang Cai
Keyword(s):  
High Speed ◽  
Contact Stiffness ◽  
Fractal Theory ◽  
Optimization Technique ◽  
Machining Accuracy ◽  
Contact Ratio ◽  
Spindle System ◽  
Machining Center ◽  
Stiffness Optimization ◽  
Optimal Stiffness

The higher contact stiffness of the double-locking toolholder-spindle (BTF40-type) joint is helpful in improving the machining accuracy and cutting stability of high-speed machining center. In this article, an optimization technique is introduced to obtain the high contact stiffness of BTF40 toolholder-spindle joint at the high speed. The torsional and radial stiffness at 25,000  r/min can be obtained by using the macro–micro hybrid method. The contact ratio of taper surface and maximum nodal pressure of contact surfaces is used as constraint conditions to ensure the connection reliability and the working life of the toolholder-spindle system. The particle swarm optimization algorithm with suitable parameters for this problem is used to search the optimal stiffness of joint automatically. The optimal stiffness of joint and pressure distribution of taper surface are compared with the initial values for validating the effectiveness of the optimization results. This research is valuable for guiding the application of BTF-type toolholder-spindle system at the high speed 25,000  r/min.

Thermal Characteristic Analyses of NC Machine Spindle System

2012 ◽  
Vol 479-481 ◽  
pp. 2481-2484 ◽  
Author(s):  
Zhong Qi Sheng ◽  
Xiang Dong Shi ◽  
Sheng Li Dai ◽  
Yan Jin
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Thermal Deformation ◽  
Thermal Characteristic ◽  
Numerical Control ◽  
Transient Temperature ◽  
Element Analysis ◽  
Spindle System ◽  
Nc Machine ◽  
Machine Spindle

This paper used finite element method to analyze thermal characteristics of numerical control (NC) machine spindle system, and studied the steady temperature field and the transient temperature field of the machine tool and the thermal deformation of the spindle at 3000 rpm. General finite element analysis software ANSYS is used for analysis. Through the analysis of the temperature field and thermal deformation of the spindle system, this paper finally obtained the deformation situation of the spindle system in thermal load. By changing the boundary conditions of the spindle system to analyze the heat distortion of the spindle system and the results showed that assembling a cooling jacket in front of the spindle box can signally reduce the thermal error of the spindle system.

Analysis and Optimization of Thermal Characteristics for NC Lathe Spindle System

2011 ◽  
Vol 341-342 ◽  
pp. 291-295
Author(s):  
Ru Fu Hu ◽  
Xiao Ping Chen ◽  
Huan Xin Yao
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Temperature Rise ◽  
High Speed ◽  
Thermal Deformation ◽  
Thermal Characteristics ◽  
Machining Accuracy ◽  
Spindle System ◽  
Modeling And Analysis ◽  
Mechanical Coupling

Improving thermal characteristics is a crucial approach for increasing machining accuracy of NC lathe. Modeling and analysis of thermal characteristics to a high speed NC lathe were implemented by using finite element method in this paper. Based on this, temperature rise characteristic of the whole spindle system was obtained. The thermal deformation of spindle system due to thermal-mechanical coupling was calculated. Layout and parameter were optimized for the radiating plate of spindle box. And this leads to a considerable reduction in the run-out error of spindle head. The optimization result reaches the expected goal.

Finite Element Analysis on Thermal Characteristics of Lathe Motorized Spindle

2011 ◽  
Vol 311-313 ◽  
pp. 2434-2439 ◽  
Author(s):  
Ping Ma ◽  
Biao Zhou ◽  
Hai Peng Li
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
High Speed ◽  
Thermal Characteristic ◽  
Thermal Characteristics ◽  
Internal Heat ◽  
Transfer Coefficients ◽  
Motorized Spindle ◽  
Element Analysis ◽  
Spindle Unit

Abstract．High-speed motorized spindle is a promising technology widely used in high speed machining．The lathe motorized spindle is the key component of the high speed NC lathe and the thermal characteristics of the lathe motorized spindle is one of the major factors influencing the performance of the machine tools．In order to improve the accuracy and reliability of the high speed NC lathe，the thermal characteristic of the high speed NC motorized spindle has been studied in this paper．Firstly，the structure feature of the spindle has been introduced and two major internal heat sources of motorized spindle have been investigated．Secondly，the heat transfer coefficients of the major components of the lathe spindle have been conducted．Then，the 2D temperature field model has been developed with finite element method．Based on it, the temperature field and temperature rises of the spindle have been simulated and the reasonability of temperature distribution of the spindle unit has also been discussed．The research results provide the reference to evaluate of the thermal behavior of the high speed NC motorized spindle．

FEA of Thermal Characteristic of Motorized Spindle Based on ANSYS Workbench

2013 ◽  
Vol 437 ◽  
pp. 36-41
Author(s):  
Kai Kang Chen ◽  
Fu Ping Li ◽  
Yong Sheng Zhao
Keyword(s):  
High Speed ◽  
Thermal Deformation ◽  
Thermal Characteristic ◽  
Thermal Error ◽  
Machining Accuracy ◽  
Motorized Spindle ◽  
Thermal Boundary Conditions ◽  
Steady State Temperature ◽  
Transient Thermal ◽  
Ansys Workbench

Thermal deformation of high-speed motorized spindle has an important effect on improving the machining accuracy. In this paper the thermal boundary conditions of thermal deformation, including the heat generation of the motor and bearing and heat transfer coefficient, are calculated to simulate the steady-state temperature field distribution, transient thermal analysis and thermal deformation in ANSYS Workbench. They provide theoretically the data for the thermal error compensation of the spindle system.

Thermal error compensation based on genetic algorithm and artificial neural network of the shaft in the high-speed spindle system

2016 ◽  
Vol 231 (5) ◽  
pp. 753-767 ◽  
Author(s):  
Chi Ma ◽  
Liang Zhao ◽  
Xuesong Mei ◽  
Hu Shi ◽  
Jun Yang
Keyword(s):  
Neural Network ◽  
Genetic Algorithm ◽  
Neural Networks ◽  
Error Compensation ◽  
High Speed ◽  
Back Propagation ◽  
Thermal Error ◽  
Machining Accuracy ◽  
Spindle System ◽  
Thermal Error Compensation

To improve the accuracy, generality and convergence of thermal error compensation model based on traditional neural networks, a genetic algorithm was proposed to optimize the number of the nodes in the hidden layer, the weights and the thresholds of the traditional neural network by considering the shortcomings of the traditional neural networks which converged slowly and was easy to fall into local minima. Subsequently, the grey cluster grouping and statistical correlation analysis were proposed to group temperature variables and select thermal sensitive points. Then, the thermal error models of the high-speed spindle system were proposed based on the back propagation and genetic algorithm–back propagation neural networks with practical thermal error sample data. Moreover, thermal error compensation equations of three directions and compensation strategy were presented, considering thermal elongation and radial tilt angles. Finally, the real-time thermal error compensation was implemented on the jig borer’s high-speed spindle system. The results showed that genetic algorithm–back propagation models showed its effectiveness in quickly solving the global minimum searching problem with perfect convergence and robustness under different working conditions. In addition, the spindle thermal error compensation method based on the genetic algorithm–back propagation neural network can improve the jig borer’s machining accuracy effectively. The results of thermal error compensation showed that the axial accuracy was improved by 85% after error compensation, and the axial maximum error decreased from 39 to 3.6 µm. Moreover, the X/ Y-direction accuracy can reach up to 82% and 85%, respectively, which demonstrated the effectiveness of the proposed methodology of measuring, modeling and compensating.

The Thermal Characteristics of the Ball Screw Feed System on a Gantry Machine Tool

2014 ◽  
Vol 490-491 ◽  
pp. 1008-1012
Author(s):  
Rui Jun Liang ◽  
Wen Hua Ye ◽  
Qun Qiang Chen ◽  
Xin Jie Zhao
Keyword(s):  
Temperature Field ◽  
Machine Tool ◽  
Thermal Equilibrium ◽  
Thermal Deformation ◽  
Thermal Structure ◽  
Ball Screw ◽  
Machining Accuracy ◽  
Feed Speed ◽  
Feed System ◽  
Gantry Machine Tool

With the increasing of machine tool feed speed, a large quantity of friction heat is generated on the ball screw system and will cause the temperature rising and thermal deformation along the ball screw that reduces the machining accuracy. The heat accumulated and dissipated are calculated to load to the established model of the Y feed system on a gantry machine tool. The stable temperature field at thermal equilibrium and the unstable temperature field before thermal equilibrium or with the variation of thermal load are gotten. From thermal structure analysis, the thermal deformation is derived. The FEM model is verified by the experiments carried out under the same condition with the simulation.

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