A dynamic loading system for high-speed motorized spindle with magnetorheological fluid

2018 ◽  
Vol 29 (13) ◽  
pp. 2754-2765 ◽  
Author(s):  
Shengli Tian ◽  
Xiaoan Chen ◽  
Ye He ◽  
Tianchi Chen ◽  
Peiming Li
Keyword(s):  
Dynamic Loading ◽  
High Speed ◽  
Dynamic Performance ◽  
Temperature Stability ◽  
Magnetorheological Fluid ◽  
Experimental Results ◽  
Motorized Spindle ◽  
Loading Test ◽  
Linear Relationships ◽  
Loading System

A high-speed dynamic loading test is a key step when testing the dynamic performance and running quality of a high-speed motorized spindle. A loading test is very difficult to perform at high speeds. Based on the rheological behavior of the magnetorheological fluid, a novel high-speed dynamic loading system for a high-speed motorized spindle was designed, fabricated, and tested. The working principles and structure of this loading system are described. The torque model of the loader was derived based on the Herschel–Bulkley model and electromagnetic simulation using the finite element method. In addition, the torque–current relationship under different speeds was analyzed by experiments, and we found non-linear relationships between the viscosity and shear stress of the magnetorheological fluid with the shear rate. The Herschel–Bulkley model was corrected by fitting for the experimental results. The loading torque, calculated by the modified model, complied with the experimental results. This lays the foundation for the design of a high-speed transmission device based on the magnetorheological shear principle. Experiments of torque stability, temperature stability, and reusability verified the feasibility and accuracy of the proposed loading system. It provides a novel method to test the dynamic loading performance of high-speed motorized spindles.

Development of Dynamic Loading Device for Rotating Spindle of Machine Tools

2012 ◽  
Vol 523-524 ◽  
pp. 544-549
Author(s):  
Ryota Sawamura ◽  
Shinya Ikenaga ◽  
Atsushi Matsubara
Keyword(s):  
Dynamic Loading ◽  
Machine Tools ◽  
High Speed ◽  
High Performance ◽  
Loading Rate ◽  
Electric Response ◽  
Loading Test ◽  
Loading Device ◽  
Magnetic Loading ◽  
The Magnetic Field

High performance milling spindles, which have high rigidity and high speed, are required for high productive machining. In order to evaluate the rigidity change of the spindle, authors has been developed a magnetic loading device. This device provides attractive force in radial direction to a dummy tool attached to a spindle. By using this device, the static stiffness of the rotating spindle has been successfully evaluated. However the loading rate could not be controlled due to the electric response lag caused by the magnetic field. To solve this problem, electric response of the coil-tool system with the air gap is analyzed and the dynamic response is estimated. The air-gap's influence on the load was also evaluated. Based on the analysis, a dynamic loading test is designed carried out for the measurement of the rigidity of a machine tool spindle.

scholarly journals Measurement Research of Motorized Spindle Dynamic Stiffness under High Speed Rotating

2015 ◽  
Vol 2015 ◽  
pp. 1-11 ◽  
Author(s):  
Xiaopeng Wang ◽  
Yuzhu Guo ◽  
Tianning Chen
Keyword(s):  
High Speed ◽  
Production Efficiency ◽  
Dynamic Stiffness ◽  
Damping Ratio ◽  
Dynamic Performance ◽  
Machining Accuracy ◽  
Motorized Spindle ◽  
Response Curves ◽  
Tool Technology ◽  
High Speed Machine

High speed motorized spindle has become a key functional unit of high speed machine tools and effectively promotes the development of machine tool technology. The development of higher speed and more power puts forward the stricter requirement for the performance of motorized spindle, especially the dynamic performance which affects the machining accuracy, reliability, and production efficiency. To overcome the problems of ineffective loading and dynamic performance measurement of motorized spindle, a noncontact electromagnetic loading device is developed. The cutting load can be simulated by using electromagnetic force. A new method of measuring force by force sensors is presented, and the steady and transient loading force could be measured exactly. After the high speed machine spindle is tested, the frequency response curves of the spindle relative to machine table are collected at 0~12000 rpm; then the relationships between stiffness and speeds as well as between damping ratio and speeds are obtained. The result shows that not only the static and dynamic stiffness but also the damping ratio declined with the increase of speed.

Research on the Dynamic Loading Method of High Speed Spindle

2011 ◽  
Vol 103 ◽  
pp. 475-479
Author(s):  
Jie Meng
Keyword(s):  
Dynamic Characteristic ◽  
Dynamic Loading ◽  
High Speed ◽  
Characteristic Curve ◽  
Loading Method ◽  
Input And Output ◽  
Loading System ◽  
Loading Modes

This paper presents a method of dynamic loading on high speed spindle used dynamometer. Based on the range of speed and power, considering the performance of different high speed spindle, two loading modes are put forward. The loading system can measure input and output parameters and draw characteristic curve of high speed spindle at one time. These methods can be used to study the dynamic characteristic of the high speed spindle, whose states at different working points are obvious.

scholarly journals Study on the Unbalanced Fault Dynamic Characteristics of Eccentric Motorized Spindle considering the Effect of Magnetic Pull

2021 ◽  
Vol 2021 ◽  
pp. 1-12
Author(s):  
Zhan Wang ◽  
Wenzhi He ◽  
Siyuan Du ◽  
Zhe Yuan
Keyword(s):  
Dynamic Model ◽  
High Speed ◽  
Air Gap ◽  
Fault Analysis ◽  
Experimental Results ◽  
Machining Accuracy ◽  
Motorized Spindle ◽  
Unbalanced Magnetic Pull ◽  
Static Eccentricity ◽  
Simulation Results

Unbalanced fault is the most common fault of high-speed motorized spindle, which is the main factor affecting the machining accuracy of high-speed spindle. Due to the unbalanced magnetic pull produced by the air gap eccentricity of the stator and rotor, the unbalanced vibration of the motorized spindle will be further aggravated. In order to explore the dynamic behavior and motion law of the unbalanced fault motorized spindle under the eccentric state, a dynamic model of the unbalanced fault of the high-speed motorized spindle considering the unbalanced magnetic pull was established. Taking the eccentric motorized spindle customized by the research group as the research object, the dynamic model is established, simulated, and analyzed, and the response change law of motorized spindle under the effect of different speed, unbalance, and air gap is obtained. The simulation results show that the unbalanced magnetic pull caused by static eccentricity will increase the unbalanced vibration of motorized spindle, and the unbalanced vibration will also increase with the increase of static eccentricity. The vibration caused by unbalanced magnetic pull does not increase with the increase of rotating speed. In frequency-domain analysis, when there is unbalanced magnetic pull, the peak appears at 0 Hz, and the amplitude of fundamental frequency vibration will increase with the increase of eccentricity. The experimental results show that the greater the eccentricity is, the greater the unbalance vibration of the motorized spindle is. The experimental results are consistent with the simulation results, which further verify the accuracy of the model. The research results lay a theoretical basis for fault analysis and diagnosis of coupling fault motorized spindle.

scholarly journals Numerical Analysis of Temperature Rise during Dynamic Loading for Dissimilar Steel Joint Specimen

2018 ◽  
Vol 941 ◽  
pp. 280-286 ◽  
Author(s):  
Yasuhito Takashima ◽  
Fumiyoshi Minami
Keyword(s):  
Temperature Field ◽  
Dynamic Loading ◽  
High Speed ◽  
Frame Rate ◽  
Loading Test ◽  
Dissimilar Steel ◽  
Steel Joint ◽  
Joint Specimen ◽  
Bonded Interface ◽  
Dissimilar Steel Joint

In this study, dynamic temperature field in a dissimilar steel joint specimen was numerically analyzed by means of three-dimensional explicit finite element analysis. Fully coupled thermal stress analysis was performed by using FE-code Abaqus/Explicit ver. 6.12. It was assumed that 90% of the plastic work was transferred to heat. Furthermore, dynamic loading tests were conducted with three-point bending specimen extracted from the dissimilar steel joint between a mild steel and a high tensile strength class steel. The specimen included a U-shape notch in the bonded interface. A high-speed infrared camera was used to measure the temperature field near the bonded interface. The temperature field was recorded at a frame rate of 200 Hz during the dynamic loading test. The numerically calculated temperature field near bonded interface showed reasonable agreement with the temperature field measured by the high-speed infrared thermography. The temperature in the soft steel particularly increased during the dynamic loading. On the other hand, the increase in temperature in the hard steel area was relatively few.

High-Speed Motorized Spindle Decoupling Optimization Control

2014 ◽  
Vol 1039 ◽  
pp. 368-375
Author(s):  
Chi Lan Cai ◽  
Ya Fei He ◽  
Ning Li ◽  
Qing Zhi Lin
Keyword(s):  
Motor Control ◽  
System Performance ◽  
High Speed ◽  
Dynamic Performance ◽  
Optimization Method ◽  
Motorized Spindle ◽  
Root Cause ◽  
Optimization Control ◽  
Motor Control System ◽  
Vibration Noise

High-speed motorized spindle is the core component of the CNC machines. Its dynamic performance directly affects the accuracy of the geometry, and be the root cause of vibration, noise and temperature increase, etc. Its motor control system has the characteristics of nonlinear and strong coupling, which is one of the key R&D items of the spindle design. Based on granular computing, this paper selects the appropriate granularity to analyze the coupling between the motor control parameters and system performance, and propose a zoning decoupling and optimization method to optimize the overall system performance, which has practical application value.

scholarly journals Thermal network model and experimental validation for a motorized spindle including thermal–mechanical coupling effect

2021 ◽  
Author(s):  
Changjiang Zhou ◽  
Zefeng Qu ◽  
Bo Hu ◽  
Shengbo Li
Keyword(s):  
Network Model ◽  
Temperature Rise ◽  
Thermal Deformation ◽  
Coupling Effect ◽  
Dynamic Performance ◽  
Experimental Results ◽  
Motorized Spindle ◽  
Mechanical Coupling ◽  
Thermal Network ◽  
Proposed Model

Abstract Thermal deformation caused by temperature rise have an influence on the dynamic performance of a motorized spindle. In turn, the change in the dynamic performance will affect the temperature rise and thermal deformation of the system. However, the latter was rarely focused on in the previous literature. Therefore, a thermal network model of motorized spindle is enhanced by considering the thermal–mechanical coupling effect. Then, an iterative method is presented to solve the coupled equations, and a temperature test rig of the motorized spindle is set up to verify the proposed model. The relative error between the predicted and experimental results at two test points decreases by 9.56% and 3.44% after considering the thermal–mechanical coupling effect. The comparison with the experimental results shows that the proposed model with thermal–mechanical coupling effect can obtain a more accurate temperature field than the previous model.

Vibration and Noise Monitoring of Ceramic Motorized Spindles

2011 ◽  
Vol 291-294 ◽  
pp. 2076-2080 ◽  
Author(s):  
Li Xiu Zhang ◽  
Yu Hou Wu
Keyword(s):  
High Speed ◽  
Dynamic Performance ◽  
High Strength ◽  
Major Elements ◽  
Motorized Spindle ◽  
High Productivity ◽  
Rotating Speed ◽  
Engineering Ceramic ◽  
Lubrication Condition ◽  
Motorized Spindles

High speed machining (HSM) technology is used in a broad range of applications to machine ferrous metals and nonmetallic material. The motorized spindle is one of the major elements to keep the machine running at high productivity. In recently years, the requirement of rotational speed and rigidity of motorized spindle is getting higher and higher in order to satisfy the high speed processing. Engineering ceramic is the ideal material for high-speed and high precision electrical spindle due to perfect characteristics of light weight, wear resistance, high temperature, high strength, and so on. So a ceramic motorized spindle is designed for higher speed and rigidity. The shaft and bearing of the motorized spindle are made from ceramic material and other parts are made from metal. Rated power of this electrical spindle is 15Kw; its torque is 14Nm and revolving speed is up to 30,000 rpm as maximum. Motorized spindle is a typical mechatronics product and its dynamic property is very important. The signal of vibration and noise of motorized spindle may display its running status, so the vibration and noise of motorized spindle is an important index in the dynamic performance. This paper monitors the vibration and noise of ceramic motorized spindles using spectral analysis techniques. The effects of rotating speed and lubrication condition on vibration and noise of the ceramic electrical spindle are analyzed. These results are very helpful to the structure optimization and application of the ceramic motorized spindle.

Reliability Test Platform for High-Speed Motorized Spindle Based on Magnetic Loading

2012 ◽  
Vol 479-481 ◽  
pp. 1031-1035 ◽  
Author(s):  
Ye Hu ◽  
Zhao Jun Yang ◽  
Xiao Ming Zeng ◽  
Jin Gan Song ◽  
Jie Fang ◽  
...  
Keyword(s):  
High Speed ◽  
Vibration Exciter ◽  
Motorized Spindle ◽  
Failure Data ◽  
Operation Conditions ◽  
Test Platform ◽  
Loading System ◽  
Torque Load ◽  
Magnetic Loading ◽  
Basic Features

In order to accurately emulate the operation conditions of high-speed motorized spindle in the reliability experiment, a dynamic loading system is proposed. This system allows simultaneously loading torque, radial and axial force against the spindle. The torque load is carried out by the electric dynamometer; the non-contact vibration exciter completes the radial load; the axial load is carried out by a self-made electromagnet. Moreover, this system also can detect out the basic features and failure data of the motorized spindle during the loading. And these sampling data provide a quantitative elevation for its reliability analysis. This paper presents a simple solution to the high-speed motorized spindle reliability research where the loading experiment is designed with the spindle whose maximum rotational speed is 18000rpm.

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