A prediction model of the surface topography due to the unbalance of the spindle system in ultra-precision fly-cutting machining

Chen, Dongju; Cui, Xianxian; Pan, Rongrong; Fan, Jinwei; An, Chenhui

doi:10.1177/1687814017747145

Cited by 5 publications

(3 citation statements)

References 25 publications

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“…They found that the imbalance in the spindle causes unbalanced magnetic forces in the motor, which ultimately affects the surface finish accuracy. In the analyses by Huang et al, 19 Chen et al, 20 and Zhang et al, 21 it was assumed that the bearing dynamic stiffness coefficient and damping coefficient were constant. However, the dynamic stiffness and damping of air bearings change with bearing clearance and rotational speeds.…”

Section: Introductionmentioning

confidence: 99%

“…They have revealed numerically the effect of the spindle imbalance and have shown that the eccentricity error motion of the spindle has a pronounced influence on the machining accuracy. Chen et al 20 performed dynamic analyses of an air spindle for ultra-precision fly cutting and investigated the effect of gas fluctuations on the aerostatic spindle on surface generation. In their study, it became clear that the rotational speeds of the spindle and the spindle imbalance directly affect the shape of the machined surface.…”

Section: Introductionmentioning

confidence: 99%

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Numerical study on the rotational and machining accuracy of an end-milling process with spindles supported by aerostatic bearings

Shimada

Wakabayashi

Shimoyakawa

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Aerostatic bearings are widely used for spindles in ultra-precision machining tools. These spindles consist of a pair of aerostatic thrust bearings and several aerostatic journal bearings. The rotational accuracy of aerostatic spindles depends largely on the arrangement and performance of the individual bearings, but the evaluation of the rotational accuracy is mainly carried out experimentally using a prototype machine, which poses challenges in terms of the time and cost of building a prototype. Therefore, a real need exists to evaluate the spindle characteristics by numerical calculation. In this study, we developed a method to numerically calculate the trajectory of the spindle rotator which is supported by aerostatic bearings. The method was developed to numerically investigate and determine the effects on the rotational accuracy of the spindle during end milling when the cutting force is applied to the rotating rotor. A comparison was made regarding the amount of runout of the rotating shaft when side milling was performed using a spindle with a shaft diameter of 22 mm and a small end mill with a diameter of 1 mm, concerning three different spindles with different arrangements of thrust and journal bearings. The effects of rotational speed, radial depth of cut, and the number of tool teeth on the runout of the rotating shaft were numerically verified. As a result, it was found that a spindle structure in which the thrust bearing is placed on the tool side and the journal bearing span is lengthened is desirable.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Numerical study on the rotational and machining accuracy of an end-milling process with spindles supported by aerostatic bearings

Shimada

Wakabayashi

Shimoyakawa

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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show abstract

“…They concluded that the bearing had better static and dynamic performance if there was an orifice located at the bottom of the bearing. Chen et al 11 discussed the effect of the unbalanced aerostatic spindle on the manufacturing surface. The conclusion indicated that rotation speed and unbalanced spindle directly affected manufacturing surface topography.…”

Section: Introductionmentioning

confidence: 99%

Numerical analysis on the performance characteristics of a new gas journal bearing by using finite difference method

et al. 2021

Advances in Mechanical Engineering

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This paper proposes a novel gas journal bearing in which orifices are different in diameter and distribute unevenly. Finite Difference Method (FDM) combined with Linear Perturbation Method (LPM) is used to solve the unsteady-state Reynolds equation of the flow field in the bearing clearance. Moreover, four types of bearing structures are used to discuss the effects of orifices different in diameter and uneven distribution on the bearing performance. The results demonstrate that the new bearing has better static and dynamic performances compared with those of traditional bearing in which orifices are equal in diameter and distribute evenly. Moreover, thin gas film thickness, high supply pressure, and large eccentricity ratio are hopeful for improving load capacity of the new bearing. Furthermore, the stability of the novel bearing is improved if eccentricity ratio is 0.25–0.3.

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Study on improving machined surface accuracy using diamond fly cutting on an ordinary milling machine

Wang

Yazawa

Han

et al. 2022

Int J Adv Manuf Technol

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A prediction model of the surface topography due to the unbalance of the spindle system in ultra-precision fly-cutting machining

Cited by 5 publications

References 25 publications

Numerical study on the rotational and machining accuracy of an end-milling process with spindles supported by aerostatic bearings

Numerical study on the rotational and machining accuracy of an end-milling process with spindles supported by aerostatic bearings

Numerical analysis on the performance characteristics of a new gas journal bearing by using finite difference method

Study on improving machined surface accuracy using diamond fly cutting on an ordinary milling machine

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