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Modeling of Spindle-Bearing and Machine Tool Systems for Virtual Simulation of Milling Operations.pdf

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Modeling of Spindle-Bearing and Machine Tool Systems for Virtual Simulation of Milling Operations

ARTICLE IN PRESS0890-6955/$ - se doi:10.1016/j.ijm Correspond E-mail addr (Y. Cao), altintInternational Journal of Machine Tools Manufacture 47 (2007) 1342–1350 /locate/ijmactoolModeling of spindle-bearing and machine tool systems for virtual simulation of milling operations Yuzhong Cao, Y. Altintas Department of Mechanical Engineering, University of British Columbia, 2054-6250, Applied Science Lane, Vancouver, BC, Canada V6T 1Z4 Received 27 June 2006; received in revised form 26 July 2006; accepted 3 August 2006 Available online 9 October 2006Abstract This paper presents a general, integrated model of the spindle bearing and machine tool system, consisting of a rotating shaft, tool holder, angular contact ball bearings, housing, and the machine tool mounting. The model allows virtual cutting of a work material with the numerical model of the spindle during the design stage. The proposed model predicts bearing stiffness, mode shapes, frequency response function (FRF), static and dynamic deflections along the cutter and spindle shaft, as well as contact forces on the bearings with simulated cutting forces before physically building and testing the spindles. The proposed models are verified experimentally by conducting comprehensive tests on an instrumented-industrial spindle. The study shows that the accuracy of predicting the performance of the spindles require integrated modeling of all spindle elements and mounting on the machine tool. The operating conditions of the spindle, such as bearing preload, spindle speeds, cutting conditions and work material properties affect the frequency and amplitude of vibrations during machining. r 2006 Elsevier Ltd. All rights reserved. Keywords: Spindle; Chatter vibration; Finite element method; Milling1. Introduction The successful application of high-speed machining technology is highly dependent on spindles operating free of chatter vibration without overloading the angular contact ball bearings. Unless avoided, vibration i