PREDICTION OF THERMAL GROWTH IN A HIGH-SPEED SPINDLE BY CONSIDERING THERMO-MECHANICAL BEHAVIOR

  • 1Manufacturing Research Laboratory, Sabanci University, Tuzla, Istanbul 34956, Turkey, Istanbul, TR
  • 2Igrek Makina Inc., OSB A.O. Sonmez Bulv. No:10 16140 Bursa, Turkey, Bursa, TR

Abstract

Continuous rotation of spindle bearings and motor cause thermally induced structural deformations and thermal growth, which is one of the main reasons for machining errors. A positive feedback loop between bearing preload and heat generation causes preload variations in spindle bearings. These preload variations demonstrate a nonlinear transient behavior until the gradual expansion of outer bearing rings after which the thermally induced preload variation behaves steadily. In this study, a Finite Element (FE) framework is presented for predicting steady preload variation on spindle bearings. The method involves a thermal loading model and a transient contact analysis. In the contact analysis phase bearing contact deformations (penetration and sliding) and pressure are predicted by considering contact algorithms in an FE software. A transient spindle simulation in FE is employed to predict the bearing temperature and thermal spindle growth by using the proposed method. The performance of the method is demonstrated on a spindle prototype through bearing temperature and thermal deformation measurements. Results show that the proposed method can be a useful tool for spindle design and improvements due to its promising results and speed without the need for tests.

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