Model-Based Design of Motorized Spindle Systems to Improve Dynamic Performance at High Speeds |
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| Institution: | 1. Dept. of Industrial Engineering and Systems Management, Feng Chia University, Taichung, Taiwan;2. Dept. of Mechanical and Aerospace Engineering, North Carolina State University, Raleigh, North Carolina, USA;1. Institute of Machine Tools and Manufacturing (IWF), Leonhardstrasse 21, ETH Zurich, 8092 Zurich, Switzerland;2. Manufacturing Automation Laboratory, Department of Mechanical Engineering, The University of British Columbia, Vancouver, BC, V6T 1Z4, Canada;1. Department of Micro-Engineering, Graduate School of Engineering, Kyoto University, Kyotodaigaku Katsura, Nishikyo-ku, Kyoto 615-8540, Japan;2. Yamazaki Mazak Corporation, 1-131 Takeda, Oguchi-cho, Niwa-gun, Aichi 480-0197, Japan;3. DMG MORI Co., Ltd., 2-35-16 Meieki, Nakamura-ku, Nagoya, Aichi 450-0002, Japan;1. Sensitec GmbH, Georg-Ohm-Straße 11, 35633 Lahnau, Germany;2. Institute of Production Management, Technology and Machine Tools (PTW), echnical University Darmstadt, Otto-Berndt-Straße 2, 64287 Darmstadt, Germany;1. Institute of Fluid Power, TU Dresden, Helmholtzstrae 7a, 01069 Dresden, Germany;1. The State Key Lab of Fluid Power Transmission and Control, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, China;2. The Key Laboratory of 3D Printing Process and Equipment of Zhejiang Province, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, China |
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| Abstract: | High-speed motorized spindle systems are subjected to several effects during high-speed rotations that can cause substantial changes in their dynamic and thermal behaviors, leading to chatter, bearing thermal seizure, or premature spindle bearing failures. Therefore, it is important to consider these high-speed effects in the design stage of high-speed motorized spindles. This paper first develops a design flow chart to represent the overall spindle design problems. Based on this flow chart, eight design parameters are identified. A design sensitivity analysis of these eight design parameters is then conducted based on an integrated finite element method model to investigate their influence on the natural frequencies of the spindle system. Based on the rule of Maximum Improvement First, a set of systematic design procedures is proposed to suggest design changes to a custom-designed motorized spindle rated at 32 kW and 25,000 rpm. Based on the simulation results, it is shown that the first-mode frequency of this spindle system can be improved from 790.7 Hz to 934 Hz at 25,000 rpm by simply adjusting the front and rear bearing locations. At the optimal design, the first-mode frequency can reach 1454.3 Hz at 25,000 rpm, which represents more than 80 percent improvement over the original design. |
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