Dynamics of ultra-high-speed (UHS) spindles used for micromachining

Bediz, Bekir; Gozen, B. Arda; Korkmaz, Emrullah; Özdoğanlar, O. Burak

doi:10.1016/j.ijmachtools.2014.07.007

Cited by 48 publications

(10 citation statements)

References 33 publications

(48 reference statements)

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“…The spindle uses a thread-in style collet, which has been seen to cause relatively large variations in the fundamental amplitude (up to 100% change) between repeated attachments (see [3]). In addition to contributing to motion at the fundamental frequency, the non-linear dynamic effects due to the centering errors [3,23,24,26] could result in motions at various harmonics of the spindle frequency, i.e., leading to synchronous motions. Hence, variations in centering errors directly affect the accurate measurement of synchronous motions.…”

Section: Evaluation Of the Methodsmentioning

confidence: 99%

“…Second, even though the lowest operational speed of the spindle was used, the fundamental component of the measured motions (caused by the centering errors and the resulting dynamic effects) between re-orientations varied as much as 100% [3]. These variations in centering errors and their dynamic effects [3,23,24,26] could result in differences in the synchronous motions between re-orientations, and hence, cause variability in the measured artifact form error when different sets of re-orientations are used.…”

Section: Orientationmentioning

confidence: 99%

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A multi-orientation error separation technique for spindle metrology of miniature ultra-high-speed spindles

Anandan

Özdoğanlar

2016

Precision Engineering

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Please cite this article in press as: Anandan KP, Ozdoganlar OB. A multi-orientation error separation technique for spindle metrology of miniature ultra-high-speed spindles. Precis Eng (2015), http://dx.a b s t r a c t This paper presents a multi-orientation error separation technique to remove the artifact form error from the radial measurements to obtain the radial spindle error motions of miniature ultra-high-speed (UHS) spindles. Unlike the existing approaches, the present technique neither relies on high-accuracy fixtures, nor necessitates measurements from specific orientations of the artifact. Rather, the spindle error motions are measured from a set of arbitrary artifact orientations using laser Doppler vibrometry (LDV). The angle of each artifact-setup orientation with respect to the spindle is determined with high precision through reflectivity measurement of the marks made on both the artifact and the spindle using another LDV. Although the presented approach can be applied by using different sensors (e.g., capacitance probes), we demonstrate the approach using LDVs. With the displacement measurement direction fixed, measurements are conducted from both LDVs for multiple orientations of the artifact. Using the unique implementation scheme developed in this paper, data from these orientations are post-processed to compute the artifact form error and further remove it from the radial motion measurements to obtain the synchronous radial spindle error motions. A thorough experimental evaluation is presented to quantify both the repeatability of the measured artifact form errors as well as the bandwidth of error separation for various number of artifact orientations. The spindle error motions measured from both the sphere and stem portions of a custom fabricated sphere-on-stem artifact mounted on a typical miniature UHS spindle, are seen to be similar in shape and within 5 nm in magnitude across the revolution, thus demonstrating the effectiveness of the technique. Using this technique, spindle error motions at ultra-high speeds up to 150 krpm were successfully quantified. Although the implementation scheme is demonstrated for miniature UHS spindles, it is readily applicable for error separation on macro-scale spindles without the need for any high-precision fixtures and precise setting of angles.

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Section: Evaluation Of the Methodsmentioning

confidence: 99%

Section: Orientationmentioning

confidence: 99%

A multi-orientation error separation technique for spindle metrology of miniature ultra-high-speed spindles

Anandan

Özdoğanlar

2016

Precision Engineering

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“…Anandan et al [10] investigated the radial and axial motions of a miniature (electrically driven) UHS spindle with hybrid ball bearings, in particular the influence of temperature fluctuations, dynamic (vibration) effects, contact bearing defects and tool-attachment errors. Bediz et al [11] examined the dynamics of a rotating UHS spindle with air bearings using a custom designed impact excitation system. Zhang et Ehmann [12] developed a design methodology for air bearing micro-spindles with a focus on controlling runout.…”

Section: Introductionmentioning

confidence: 99%

Design and Development of a High Efficiency Air Turbine Spindle for Small-Part Machining

Harris

Wintterer

Jasper

et al. 2019

Int. J. of Precis. Eng. and Manuf.-Green Tech.

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This paper reports on the development of a high efficiency and low inertia miniature pneumatic turbine for ultra-high-speed manufacturing spindle applications. It is proposed that radial-inflow/axial-outflow type turbines are well suited for micromachining spindles. To validate the turbine performance potential, a proof-of-concept prototype turbo-spindle was developed and experimentally tested. The prototype spindle produced a net mechanical power output of over 60 W at a speed of 90,000 rpm. The experimental results demonstrate a micro-turbine efficiency of over 50% and a turbine power output of approximately 100 W. This compares to a typical turbine efficiency of around 20% in commercial micro-machining spindles. Further potential improvements to both turbine and spindle energy efficiency are outlined.

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“…The traditional static test or stationary condition evaluation of the motorized spindle may not truly express the performance under these varying operation conditions. In recent years, Bediz et al [12] and Ritou et al [13] testified the dynamic response of spindles under different loads and rotating speed. However, the modal tests emphasize the identification of modal parameters, rather than the rotating performance, leading to the distinction in test signals and load pattern from the actual cutting loads.…”

Section: Introductionmentioning

confidence: 99%

Load-Dependent Rotating Performance of Motorized Spindles: Measurement and Evaluation Using Multi-Zones Error Map

et al. 2019

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The rotating performance of motorized spindles is critical to the dimensional accuracy and surface quality of the parts to be machined. This paper proposes a novel measurement strategy and an evaluation method of spindle's rotating performance, considering the loads imposed on the spindle. To be specific, cutting loads are simplified as a unified function to guide the load simulation, and the load-induced error is eliminated using a position adjustment procedure. In a certain speed-load combination, the spindle's rotating performance under the unified load function is measured using a data envelope method. To extend the assessment to all typical work conditions, an evaluation scheme for different speed and load combinations is proposed based on a visual ideal of Multi-Zones Error Map (MZE Map). The necessity of considering the load-dependent rotating performance is demonstrated via several tests conducted on proposed load simulation platform. Besides, the procedures for developing the MZE Map are performed, and the results express an overview relationship between rotating performance and different speed-load conditions. The proposed method provides a new approach to evaluate the rotating performance considering the actual load conditions. This load-dependent oriented evaluating strategy contributes to a more precise health evaluation and management method for motorized spindles in actual machining process.INDEX TERMS Rotating machines, load modeling, performance evaluation, prognostics and health management.

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Dynamics of ultra-high-speed (UHS) spindles used for micromachining

Cited by 48 publications

References 33 publications

A multi-orientation error separation technique for spindle metrology of miniature ultra-high-speed spindles

A multi-orientation error separation technique for spindle metrology of miniature ultra-high-speed spindles

Design and Development of a High Efficiency Air Turbine Spindle for Small-Part Machining

Load-Dependent Rotating Performance of Motorized Spindles: Measurement and Evaluation Using Multi-Zones Error Map

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