Coupled Thermal and Fluid Mechanical Modeling of a High Speed Motor Spindle

Koch, L.; Müller, Julian; Michos, Gordana; Paulus, Johannes; Hubert, Markus; Franke, Jörg

doi:10.4028/www.scientific.net/amm.871.161

Cited by 3 publications

(3 citation statements)

References 19 publications

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“…2, right) was a Finite-Element-Model (FEM) with an additionally coupled Computational-Fluid-Dynamics (CFD) simulation for the fluid cooling systems inside the spindle housing. The first version of the spindle simulation model was based on a set of boundary conditions published in our previous works on a spindle with 18,000 rpm [3,18]. However, the empirical observation showed that this set of boundary conditions could not be conveyed to the test specimen of the analysis with 40,000 rpm.…”

Section: General Approachmentioning

confidence: 99%

“…Figure 1 visualizes available models and their speed. Most publications [5][6][7][8][9][10][11][12][13][14][15][16][17][18] do not consider motorized spindles with more than 18,000 rpm. The recent addition of Denkana [19] showed modeling efforts for a spindle with 20,000 rpm.…”

Section: Introductionmentioning

confidence: 99%

“…Wu [7] Cao [8] Syath [9] Vyroubal [13] Ma [14] Wang [15] Chen [16] Zhao [6] Liu [10] Nikitina [11] Uhlmann [12] Gebert [21] Udup [5] Huang [17] Koch [18] Denkana [19] bearing friction bearing and air friction Unfortunately, Bossmanns' and Gebert's approaches to quantify the bearing friction cannot be transferred to different spindles without extensive measuring effort. This paper presents a newly developed set of boundary conditions for high-speed motorized spindles, which was validated at 40,000 rpm.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Thermal Modeling Challenges of High-Speed Motorized Spindles

Koch

Butz²,

Kruger

et al. 2023

Lecture Notes in Production Engineering

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This paper investigates the thermal modeling challenges of high-speed motorized spindles up to 40,000 rpm. The thermal expansion and deflection of motorized spindles are critical determinants for the resulting tool center point displacement and the achievable machining accuracy of machine tools. In order to compensate, finite element and reduced physical models (digital twins) therefore require an accurate understanding of the thermal boundary conditions. In motorized spindles, heat sources are of great significance to the resulting temperature field. However, it is very difficult to accurately quantify the heat sources in motorized spindles. This is a particular challenge for high-speed applications exceeding 20,000 rpm, where commonly used boundary conditions are not validated. While the power loss of the electric motor could be quantified with reasonable accuracy, the calculation approaches for air and bearing friction proved to be inadequate. This paper introduces approaches to quantify the air and bearing friction of motorized spindles with improved accuracy for applications up to 40,000 rpm. The method was verified based on a coupled thermal/fluid-mechanical spindle simulation model. The mean absolute temperature difference between the model and the test bench was 1.5 K.

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Section: General Approachmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Thermal Modeling Challenges of High-Speed Motorized Spindles

Koch

Butz²,

Kruger

et al. 2023

Lecture Notes in Production Engineering

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Improving the Thermal Behavior of High-Speed Spindles Through the Use of an Active Controlled Heat Pipe System

Jonath,

Luderich,

Brezina

et al. 2023

Lecture Notes in Production Engineering

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The thermo-elastic behavior of high-speed spindles has a significant influence on the machine accuracy. The Tool Center Point (TCP) changes continuously, not only due to the different temperature levels and energy inputs during warm-up, full-load and part-load operation, but also during interruptions for workpiece or tool changes. In this paper a heat pipe based tempering system is presented to control the spindle temperature and thus to keep the TCP displacement at a constant level, regardless of speed and load. As effective passive heat transfer components, heat pipes can be used not only to cool the system but also to insert heat into it. This capability of reversing the heat flow enables a high controllability of the temperature field in a bidirectional way and allows innovative capabilities of using advanced control algorithms. This paper describes the overall heat pipe concept and focuses on its potential as a key element for dynamic temperature control systems. Experimental results prove the feasibility of the concept with a simple on-off controller, achieving the reduction of the TCP displacement variation of a 2.2 kW spindle by 62% of its original value. The potential of the tempering concept forms the base for the deployment of various advanced control systems, such as Model-based Predictive Control (MPC), Fuzzy or Reinforcement Learning.

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A review of research on thermal characteristics and cooling strategies of high-speed motorized spindles

Li,

Zhang,

2024

J Therm Anal Calorim

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Coupled Thermal and Fluid Mechanical Modeling of a High Speed Motor Spindle

Cited by 3 publications

References 19 publications

Thermal Modeling Challenges of High-Speed Motorized Spindles

Thermal Modeling Challenges of High-Speed Motorized Spindles

Improving the Thermal Behavior of High-Speed Spindles Through the Use of an Active Controlled Heat Pipe System

A review of research on thermal characteristics and cooling strategies of high-speed motorized spindles

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