• Journal of the Korean Society for Precision Engineering
• /
• v.11 no.1
• /
• pp.123-128
• /
• 1994

A high speed spindle system for machine tools can be used to reduce the machining time, to improve the machining accuracy, to perform the machining of light metals and hard materials, and to unite the cutting and grinding processes. In this study, a high speed spindle system is developed by applying the oil-air lubrication method, angular contact ball bearings, injection nozzles with dual orifices, cooling jacket and so on. And an air cooling experiment for evaluating the performance of the spindle system is carried out. Especially, in ofder to establish the air cooling conditions related to the development of a high speed spindle system, the effects of cooling air pressure, oil supply rate, air supply rate and rotational spindle speed are studied and discussed on the bearing temperature rise and frictional torque. Also the effects of cooling air pressure, rotational spindle speed and spindle system structure is investigated on the bearing temperature distribution. The experiment on the test model reveals the usefulness of the air cooling method.

• Journal of the Korean Society of Manufacturing Technology Engineers
• /
• v.8 no.1
• /
• pp.28-34
• /
• 1999

According to the development of tool material and the improvement of machinability of cutting material like aluminium alloy, the higher spindle speed is needed. However, the higher speed causes the heat generation of bearings, the deformation of spindle unit parts, and the rotational accuracy of spindle to be worse. Therefore, it is essential to analyze and control the heat generation and the thermal behavior of spindle unit in order to have higher speed and better rotational accuracy. This paper shows the analogy between the analyzation of heat generation and thermal behavior of high speed spindle system by finite element method and the test results of actual temperature rise through running test, and shows the necessity of cooling the spindle and inner ring side of bearings for the thermal balance of high speed spindle system.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2004.04a
• /
• pp.439-444
• /
• 2004

The important problem in high speed spindle is to reduce and minimize the thermal effect by motor and ball bearings. In this study. the effects of bearing preload and cooling for high speed spindle with high frequency motor are investigated. A high speed spindle is composed of angular contact ball bearings, high frequency motor, grease lubrication, oil jacket cooling, and so on. Heat generation of the bearing and the high frequency motor are estimated from the theoretical and experimental data. The thermal analyses of high speed spindle to minimize the thermal effect and maximize the cooling effect are carried out under the various cooling conditions and preload. Method of variable bearing preload and cooling can be useful to design the high speed motor spindle. The results show that the optimal preload and cooling are very effective to minimize the thermal displacement by motor and ball bearing.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2000.11a
• /
• pp.987-992
• /
• 2000

In a high speed spindle system, it is very important to monitor the operation of the spindle to prevent catastrophic damage to the system. Widely used sensors for monitoring are eddy-current and capacitive types. These sensors provide high accuracy of monitoring, but their steep prices lead to expensive high speed spindle systems. The main goal of our research is to develop technology for producing high speed spindle system utilizing magnetic bearings. As active magnetic bearings require position sensors for feedback control, a noncontact position sensor is being developed as a part of this main goal. Once developed, it will contribute to affordable high speed spindle system. This paper describes the selection process of the sensor types and the design of the driving circuit. We also report the experimental results that characterize the static and dynamic performances of the inductive sensor.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2005.06a
• /
• pp.1749-1752
• /
• 2005

High speed machining has become the main issue of metal cutting. Due to increase of the rotational speed of the spindle, problems, such as the run-out errors, reduced stiffness, must be overcome to improve the machining accuracy. In order to solve the problems, it is important to determine the appropriate clamping unit and tooling system. This paper presents an investigation into an evaluation of contact interval which is the interface between spindle taper hole and tool holder shank of the spindle. Finite element analysis is performed by using a commercial code ANSYS according to variation of clamping forces and rotational speeds. This paper proposed fit tolerance in order to evaluate the effects of clamping force and rotational speed on the contact interval in the spindle interface. From the finite element results, it has been shown that the rotational speed rather than clamping force mostly influence on the variation of the contact interval.

• Journal of the Korean Society for Precision Engineering
• /
• v.23 no.3 s.180
• /
• pp.147-155
• /
• 2006

High speed machining has become the main issue of metal rutting. Due to increase of the rotational speed of the spindle, problems, such as the run-out errors, reduced stiffness, must be overcome to improve the machining accuracy. In order to solve the problems, it is important to determine the appropriate clamping unit and tooling system. This paper presents an investigation into an evolution of contact interval which is the interface between spindle taper hole and tool holder shank of the spindle. Finite element analysis is performed by using a commercial code ANSYS according to variation of clamping forces and rotational speeds. This paper proposed fit tolerance in order to evaluate the effects of clamping force and rotational speed on the contact interval in the spindle interface. From the finite element results, it has been shown that the rotational speed rather than clamping force mostly influence on the variation of the contact interval.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2000.06a
• /
• pp.109-115
• /
• 2000

The spindle unit is core parts in high precision machine tools. Diverse static, dynamic and thermal charateristics of spindle unit are needed for special purpose of machine tools. Compromise between those charateristics will be done in concept design phase. High static stiffness at spindle nose may be very important performance for heavy cutting work. High dynamic stiffness is also useful to high precision and high speed machine tools. Improvement of thermal charateristics in spindle lead to high reliability of positioning accuracy. For high speed spindle structure, the design parameter such as, bearing span, diameter, bearing type and arrangement, preload, cooling and lubrication method should be in harmony.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 1999.10a
• /
• pp.227-230
• /
• 1999

In this paper, the machining characteristics of high speed ball end milling affected by the rotational error of high speed spindle using air bearing are investigated. The error motions of a spindle have generally influenced on the surface roughness, the form accuracy, the tool life, etc. in end milling. Experiments are carried out over a wide range of rotational speeds(10,000-50,000rpm). The rotational errors of the spindle are measured by the gap sensor mounted on the spindle shaft at various cutting speeds. The relations between the surface roughness and the spindle error motion are presented. Results show that the rotational accuracy of the spindle directly affects the surface roughness of the machined surface.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2004.04a
• /
• pp.398-403
• /
• 2004

The demand of high speed machining is increasing because the high speed cutting providers high efficiency of process, short process time, improved metal removal capacity and better surface finish. Active magnetic bearings allow much high surface speed than conventional ball bearings and therefore greatly suitable for high speed cutting. The automatic control concept of magnetic bearing system provides ability of intelligent control of spindle system to increase accuracy and flexibility by means of adaptive vibration control. This paper describes a design and development of a milling spindle system which includes built-in motor with power 5.5㎾ and maximum speed 70,000rpm, HSK-32C tool holer and active magnetic bearing system. Magnetic actuators are designed for satisfying static load condition. The Performances of manufactured spindle system was examined for its static and dynamic stiffness, load capacity, and rotational accuracy. This spindle was run up to 70,000 rpm stably, which is 3.5 million DmN.

• Journal of the Korean Society for Precision Engineering
• /
• v.26 no.7
• /
• pp.120-126
• /
• 2009

Thermal displacement of high speed spindle is very important problem to be solved. To solve heat generation and thermal displacement problems that influence on the product accuracy, it is very important to predict thermal characteristics of the spindle and it is positively necessary to select the conditions of cooling, flow rate and preload of bearings. In this paper, 30,000rpm($1.455{\times}10^6DmN$) spindle was designed and produced. The analysis of thermal deformation for heat generation of inner spindle was carried out using commercial program $ANSYS^{(R)}$ and the result was compared with measured data using $LabVIEW^{(R)}$ and SGXI-1600, 1125 and 1126 module. Temperature distribution and thermal displacement according to spindle speed are measured. Using this method, it is possible to predict and to improve thermal characteristic of high speed spindle by control spindle speed, bearing preload and cooling rate.