Thermal-mechanical dynamic interaction in high-speed motorized spindle considering nonlinear vibration

Jin, Hao; Li, Changyou; Song, Wenjun; Yao, Zhenghong; Miao, Huihui; Xu, Ming; Gong, Xiaoxuan; Lu, Hanqing; Liu, Zhendong

doi:10.1016/j.ijmecsci.2022.107959

Cited by 38 publications

(7 citation statements)

References 117 publications

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“…By integrating the Maxwell stresses along the projected directions of the X and Y axes and the additional transverse electromagnetic moments along the X and Y axes, the unbalanced magnetic tensile forces in the four directions are obtained [51] :…”

Section: Rotor Eccentricity Modelmentioning

confidence: 99%

The vibration analysis of a high-speed motorized spindle system considering nonsmooth bearing restoring force and unbalanced magnetic pulling force

Zhang,

Ma,

Jiang

2023

Preprint

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As an important equipment in the field of modern machining, high-speed motorized spindle has a broad application prospect and important research significance. This paper focuses on the dynamic behaviour of high-speed motorized spindle systems. By using the lumped mass method to simplify the motorized spindle system, nonlinear factors such as Hertz contact and bearing time-varying stiffness are considered in the model. In addition, the effects of unbalanced magnetic force and unbalanced mass on the whole system are considered.On this basis, a system of 18-degree-of-freedom differential equations is established to describe the motion of the system. The effects of spindle speed, rotor eccentricity, air gap eccentricity and bearing parameters on the vibration behaviour and stability of the spindle are investigated using analytical methods such as bifurcation diagrams, time-domain waveforms, spectra, trajectories and Poincaré sections. The results show that the variation of spindle speed and bearing parameters has a significant effect on the vibration behaviour and stability of the spindle. The study provides a valuable reference for the design and optimisation of motorized spindle systems and bearing selection.

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Section: Rotor Eccentricity Modelmentioning

confidence: 99%

The vibration analysis of a high-speed motorized spindle system considering nonsmooth bearing restoring force and unbalanced magnetic pulling force

Zhang,

Ma,

Jiang

2023

Preprint

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“…Consequently, the thermal-induced variations in the structural characteristics of the spindle system were expected to have an impact on the dynamic behavior of the milling machine and its machining accuracy [27][28][29][30][31]. Gao et al [27] developed a Finite Element model of a spindle using the Timoshenko beam theory to analyze the thermal-induced bearing preload and stiffness.…”

Section: Introductionmentioning

confidence: 99%

Development of a Digital Model for Predicting the Variation in Bearing Preload and Dynamic Characteristics of a Milling Spindle under Thermal Effects

Arief,

Lin,

Royandi

et al. 2024

Lubricants

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The spindle tool is an important module of the machine tool. Its dynamic characteristics directly affect the machining performance, but it could also be affected by thermal deformation and bearing preload. However, it is difficult to detect the change in the bearing preload through sensory instruments. Therefore, this study aimed to establish a digital thermal–mechanical model to investigate the thermal-induced effects on the spindle tool system. The technologies involved include the following: Run-in experiments of the milling spindle at different speeds, the establishment of the thermal–mechanical model, identification of the thermal parameters, and prediction of the thermal-induced preload of bearings in the spindle. The speed-dependent thermal parameters were identified from thermal analysis through comparisons with transient temperature history, which were further used to model the thermal effects on the bearing preload and dynamic compliance of the milling spindle under different operating speeds. Current results of thermal–mechanical analysis also indicate that the internal temperature of the bearing can reach 40 °C, and the thermal elongation of the spindle tool is about 27 µm. At the steady state temperature of 15,000 rpm, the bearing preload is reduced by 40%, which yields a decrease in the bearing rigidity by approximately 16%. This, in turn, increases the dynamic compliance of the spindle tool by 22%. Comparisons of the experimental measurements and modeling data show that the variation in bearing preload substantially affects the modal frequency and stiffness of the spindle. These findings demonstrated that the proposed digital spindle model accurately mirrors real spindle characteristics, offering a foundation for monitoring performance changes and refining design, especially in bearing configuration and cooling systems.

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“…Bearing heating, as a key influencing factor, brings about the temperature rise and thermal deformation of bearings, and subsequently, the contact and friction states between bearing parts are changed (Hao et al , 2023). Consequently, the bearing rotation error increases, and this will inevitably lead to the degradation of the service accuracy and life of spindles.…”

Section: Introductionmentioning

confidence: 99%

“…To this end, numerous analytical works on ball bearing conductance were carried out in three key fields: contact heat transfer, heat conduction and convection of bearings. (Cao et al , 2018; Xiong et al , 2022; Hao et al , 2023).…”

Section: Introductionmentioning

confidence: 99%

“…Based on these findings, Zheng and Chen (2020) presented a multi-node thermal grid with structural constraints. In addition, Li et al (2017) factored the tilting error of outer rings into a quasi-static model to explore the assembly error influence on rolling bearing heating; Niel et al (2019) developed a simplified thermal grid model of bearings, in which only the external geometry parameters of bearings are needed when determining the bearing ring temperature; and Hao et al (2023) considered thermal and dynamical characteristics to present a new closed-loop iterative modeling method to improve the modeling accuracy of thermal networks.…”

Section: Introductionmentioning

confidence: 99%

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An efficient thermal model for high-speed angular contact ball bearings based on oil-air two-phase flow and gray-box model

Zheng,

Zheng

2023

ILT

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Purpose For a lightweight and accurate description of bearing temperature, this paper aims to present an efficient semi-empirical model with oil–air two-phase flow and gray-box model. Design/methodology/approach First, the role of lubricant/coolant in bearing temperature was discussed separately, and the gray-box models on the heat convection inside a bearing cavity were also created. Next, the bearing node setting scheme was optimized. Consequently, a novel semi-empirical two-phase flow thermal grid for high-speed angular contact ball bearings was planned. With this model, the thermal network for the selected motored spindle was built, and the numerical solutions for bearing temperature rise were obtained and contrasted with the experimental values for validation. The polynomial interpolation on test data, meanwhile, was also performed to help us observe the temperature change trend. Finally, the simulations based on the current models of bearings were implemented, whose corresponding results were also compared with our research work. Findings The validation result indicates that the thermal prediction is more accurate and efficient when the developed semi-empirical oil–air two-phase flow model is employed to assess the thermal change of bearings. Clearly, we provide a more proper model for the thermal assessment of bearing and even spindle heating. Originality/value To the best of the authors’ knowledge, this paper introduced the oil–air separation and gray-box model for the first time to describe the heat exchange inside bearing cavities and accordingly presents an efficient semi-empirical oil–air two-phase flow model to evaluate the bearing temperature variation by using thermal network method. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2023-0180/

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Thermal-mechanical dynamic interaction in high-speed motorized spindle considering nonlinear vibration

Cited by 38 publications

References 117 publications

The vibration analysis of a high-speed motorized spindle system considering nonsmooth bearing restoring force and unbalanced magnetic pulling force

The vibration analysis of a high-speed motorized spindle system considering nonsmooth bearing restoring force and unbalanced magnetic pulling force

Development of a Digital Model for Predicting the Variation in Bearing Preload and Dynamic Characteristics of a Milling Spindle under Thermal Effects

An efficient thermal model for high-speed angular contact ball bearings based on oil-air two-phase flow and gray-box model

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