A model-based cooling strategy for motorized spindle to reduce thermal errors

Grama, Srinivas N.; Mathur, Ashvarya; Badhe, Ashok N.

doi:10.1016/j.ijmachtools.2018.04.004

Cited by 87 publications

(32 citation statements)

References 21 publications

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“…Such corrective measures are often carried out for thermal stabilization of the entire machine or individual structural units (e.g., [51][52][53][54][55][56][57][58][59][60]). However, as motor spindles are usually the main sources of heat, there are a series of studies that deal with the modeling of spindles and their metrological investigation for the identification of correction values (e.g., [41,[61][62][63][64][65][66][67][68][69][70][71][72]). A review on this topic is given in [73].…”

Section: Influence Of Thermal Load On Manufacturing Accuracymentioning

confidence: 99%

Cooling of motor spindles—a review

Denkena

Bergmann

Klemme

2020

Int J Adv Manuf Technol

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Thermally induced loads in motor spindles can cause a number of undesired effects. As a result, the process capability of spindles, and thus, the productivity of a process can decrease. Future motor spindles will be exposed to higher mechanical and especially thermal loads due to trends aiming to increase power densities and maximum speeds. These trends are amplified by increasingly powerful drive concepts and developments in bearing technology. Therefore, researchers assume that it will not be possible to raise the performance potential of spindles due to insufficient cooling of its heat sources. A series of different cooling concepts have been researched and developed in recent decades. These developments have been made for different purposes. They also differ considerably in terms of their cooling principles and cooling performance. In this article, these cooling approaches and the motivations for their development are described. Firstly, the causes of heat development in motor spindles are described in a historical context. Subsequently, the effects of heat development on the manufacturing-relevant properties of motor spindles are revealed. Finally, current deficits in the area of spindle cooling and the need for the development and transfer into industrial practice of more efficient and cost-effective cooling concepts to overcome future challenges are discussed.

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Section: Influence Of Thermal Load On Manufacturing Accuracymentioning

confidence: 99%

Cooling of motor spindles—a review

Denkena

Bergmann

Klemme

2020

Int J Adv Manuf Technol

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“…However, the cooling oil flow is not controlled for different spindle loads. Grama and Badhe [21] adapted the on-off compressor control to offer the constant supplied coolant temperature for the spindle by calculating the generating heat from the spindle through measuring the temperatures of the front and rear bearings and the motor. It is found the thermal deformation of Z-axis can be reduced by more than 6.4 µm.…”

Section: Temperature Difference T Imentioning

confidence: 99%

Enhancement of Machining Accuracy Utilizing Varied Cooling Oil Volume for Machine Tool Spindle

Luo

Hong

et al. 2020

IEEE Access

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In this study, varied cooling oil volume (VOV) control was developed for the oil coolant of a machine tool. This allows adjustment of the oil circulation flow rate in terms of the machining loads and rotational speeds of the spindle to remove the generated heat effectively from the spindle. A mathematical model of the cooling oil flow rate in terms of the rotating speed and torque of the spindle for VOV method is developed. From the thermal deformation experiments with the VOV method, the thermal deformations in both the Y-axis and Z-axis can be greatly reduced, by 70.1 % and 73.5 %, respectively, in variable rotational speed operation with a short operational period (10 minutes). Moreover, the VOV method was applied to shorten the required warm-up time of the spindle. The required warm-up time of the spindle can be shortened by 50 %, while the three axes of the spindle attain stable thermal conditions. In practical machining experiments, the machining accuracy with the VOV method can be greatly enhanced by 34 % to 62 % in comparison with the current case of constant cooling oil volume (COV). The VOV control system in the machine tool spindle can effectively reduce the thermal deformation and shorten the required warm-up time. In addition, the machining accuracy can be greatly enhanced. INDEX TERMS Thermal deformation, thermal suppression, varied cooling oil volume, machining accuracy.

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“…The spindle housing lower end T 3 , T 4 The spindle housing substructure T 5 , T 6 The spindle housing central structure…”

Section: Thermal Error At Different Speedsmentioning

confidence: 99%

“…The largest gray comprehensive correlation degree was selected as the optimal measuring point, that is, ρ 1,9 = 0.5674 was the maximum. Above all, the placement locations of [2], [3], [4], [5], [6], [7], [8], [9], [10], [11], [12] 0.8376 10 [1,9,10], [2], [3], [4], [5], [6], [7], [8], [11], [12] 0.8272 9 [1,2,9,10], [3], [4], [5], [6], [7], [8], [11], [12] 0.8114 8 [1,2,6,9,10], [3], [4], [5], [7], [8], [11], [12] 0.7819 7 [1,2,4,6,…”

Section: Optimization Analysis Of Temperature-sensitive Pointsmentioning

confidence: 99%

“…Machine tool thermal error is the main factor causing the reduction of machining accuracy and accounts for 40-70% of total errors [1][2][3]. There are two methods used to reduce machine tool thermal errors [3]: reducing thermal deformation by improving structural designs and controlling thermal errors from heat transfer and dissipation, such as the introduction of an additional equilibrium heat source or auxiliary cooling device, and increasing the rigidity of machine tools [4,5]. However, the second method requires modifying the machine tool structure and increasing the cost.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Thermal error modeling of CNC milling machining spindle based on an adaptive chaos particle swarm optimization algorithm

Yue

Guo

et al. 2020

J Braz. Soc. Mech. Sci. Eng.

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The thermal error of machine tool spindle system has become an important factor affecting machining accuracy. Measurement experiments of a 3-axis vertical milling machine spindle system were conducted to assess temperature fields and thermal errors. The fuzzy clustering and gray correlation algorithms were adopted to cluster the temperature measuring points and identify the temperature-sensitive points. Based on the adaptive chaos particle swarm optimization algorithm, thermal error models were established in the axial and radial directions for the spindle system, and the compensation effects were evaluated by the workpiece machining accuracy. The results showed that the number of temperature measuring points was reduced from 12 to 6. The residual range of measured and predicted thermal error values in the axial direction was 6.17-4.19 μm, and the modeling accuracy was 95.53%. The radial residual ranges were − 2.75-3.05 μm and − 2.10-2.15 μm, and the modeling accuracies were 90.74% and 91.10%, respectively. The model compensation effect was demonstrated remarkably in the verification experiments. The thermal error models showed high prediction precision, could improve machining accuracy and had strong engineering application value.

show abstract

A model-based cooling strategy for motorized spindle to reduce thermal errors

Cited by 87 publications

References 21 publications

Cooling of motor spindles—a review

Cooling of motor spindles—a review

Enhancement of Machining Accuracy Utilizing Varied Cooling Oil Volume for Machine Tool Spindle

Thermal error modeling of CNC milling machining spindle based on an adaptive chaos particle swarm optimization algorithm

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