Ball Screw Selection and Calculations

ME EN 7960 Precision Machine Design

Topic 4

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-1

Ball Screw Selection Criteria

Maximum Rotational
Speed
Resonance (bending)
of threaded shaft
DN value

Applied Load
Thrust force
Required torque

Ball Screw
Selection

Ball Screw Life

Basic dynamic load
rating

Accuracy

Stiffness

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-2

Based on Load
A ball screw transforms rotational motion into
translational motion. As a result, the shaft is subject to
loads:
Thrust force (the sum of all external forces such as machining
load, gravity, friction, inertial forces, etc.).
Torque required to generate the thrust force.

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-3

Driving Torque to Obtain Thrust

Fl
T= a
2

T:
Fa:
l:
:

driving torque [Nm]

thrust force [N]
screw lead [m]
efficiency

Source: THK Co., Ltd.

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-4

Required Thrust
The thrust is the sum of all forces acting in the axial
direction.

Fa = FM + F f + Fi + Fg

FM:
Ff:
Fi:
Fg:

Machining force [N]

Frictional force [N]
Inertial force [N]
Gravitational force [N]

Source: THK Co., Ltd.

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-5

Stresses from Applied Loads

axial =

Fa
rtr2

torsional =

2T
rtr3

The equivalent (Von Mises) stress:

2
2
eq = axial
+ 3 torsional

eq =

4 Fa
12l 2
+
1
d tr2
2 d tr2 2
max:

Permissible stress [147 MPa]

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-6

Graphic Solution
Von Mises Stress in Shaft (Fa = 2344N)

3 .10

1mm lead
2mm lead
4mm lead
5mm lead

Von Mises Stress [Pa]

2.5 .10

2 .10

1.5 .10

max

= 147 MPa

1 .10

5 .10

0
0.001

0.002

0.003

0.004

0.005

0.006

0.007

Root Diameter [m]

0.008

0.009

1mm lead -> dtr > 4.6mm

2mm lead -> dtr > 4.8mm
4mm lead -> dtr > 5.2mm
5mm lead -> dtr > 5.5mm

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-7

Permissible Compressive Load

Buckling Load

P1 =

EI
2

lb2

P1:
lb:
E:
I:
:

Buckling load [N]

Distance between mounting positions [m]
Elastic modulus [Pa]
Second moment of inertia [m4]
Support factor
Fixed free:
= 0.25
Fixed supported:
= 2.0
Fixed fixed:
= 4.0

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-8

Fixed-Free Mount

Source: THK Co., Ltd.

Inexpensive but only applicable for short ball screws and/or slow speeds.

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-9

Fixed-Supported Mount

Source: THK Co., Ltd.

Most commonly used mounting setup.

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-10

Fixed-Fixed Mount

Source: THK Co., Ltd.

Overconstrained mounting setup for applications where high stiffness,

accuracy, and high shaft speed is required. Ball screw needs to be prestretched to avoid buckling in the case of thermal expansion.

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-11

Basic Static Load Rating Coa

When ball screws are subjected to excessive loads in static
condition (non rotating shaft), local permanent deformations are
caused between the track surface and the steel balls.
When the amount of this permanent deformation exceeds a
certain degree, smooth movement will be impaired.

Coa f s Fa

Coa:
f s:
Fa:

Basic static load rating [N, kgf, lbf]

Static safety factor
Load on shaft in axial direction [N, kgf, lbf]

Use conditions

fs (lower limit)

Normal operation

1.0 2.0

Operation with impacts and vibrations

2.0 3.0

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-12

Permissible Speed
When the speed of a ball screw increases, the ball screw
will approach its natural frequency, causing a resonance
and the operation will become impossible.

nc =

602
2
2lb

EI
A

152 d tr
=
2lb2

nc:
lb:
E:
I:
:
A:
:

Critical speed [min-1]

Distance between supports [m]
Elastic modulus [Pa]
Second moment of inertia [m4]
Density [kg/m3]
Root cross sectional area [m2]
Support factor
Fixed free:
= 1.875
Supported supported:
= 3.142
Fixed supported:
= 3.927
Fixed fixed:
= 4.730

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-13

Spindle Speed and DN Value

Shaft speed

n=

va
l

n:
va:
l:

Revolutions per second [s-1]

axial speed [m/s]
lead [m]

D:
N:

Ball circle diameter [mm]

Revolutions per minute [min-1]

DN Value. Unless specified

otherwise:

DN 70000

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-14

Dynamic Load Rating Ca and Life

The basic load rating Ca is the load in the shaft direction
with 90% of a group of the same ball screws operating
individually will reach a life of 106 (1 million) revolutions.
3

C
L = a 106
f w Fa

L:
Ca:
fw:
Fa:

Rotation life [rev]

Basic dynamic load rating [N, kgf, lbf]
Load factor
Load in shaft direction [N, kgf, lbf]

Use conditions

fw

Smooth movement without impacts

1.0 1.2

Normal movements

1.2 1.5

Movement with impacts and vibrations

1.5 2.5

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-15

Example

Mass of axis: 350kg

Maximum velocity: 20m/min
Acceleration time: 0.05s
Bearing friction factor: 0.003
Machining force: 500N
Length of work piece: 500mm
Length of travel at maximum speed: 100mm
Orientation of axis: horizontal

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-16

Machining Profile of Making a Slot

Machining speed
Maximum speed

Work piece

Variable speed

vmax

v0 = 0
v1 = vm

ax

v2 = vm

ax

v3 = vm
v4 = vm

vm

v5 = 0
v6 = vm

-vm

v7 = vm
v8 = vm

ax

vr = vm

ax

v1 0 = 0

-vmax
ME EN 7960 Precision Machine Design Ball Screw Calculations

4-17

Load Profile for Making a Slot

0 1

2 3

4 5 6

7 8

910

V,F
vmax
v0 = 0

Fa1 = Fi + F f = 2344N

v1 = vmax

Fa 2 = F f = 10 N

v2 = vmax
v3 = vm

t v4 = vm

vm

v5 = 0

-vm

v6 = vm
v7 = vm
v8 = vmax
vr = vmax
v10 = 0

Fa 3 = Fi + F f i = 2324N
Fa 4 = Fm + F f = 510 N
Fa 5 = F f = 10 N
Fa 6 = F f = 10 N
Fa 7 = Fm F f = 510 N
Fa 8 = Fi F f = 2344N
Fa 9 = F f = 10 N
Fa10 = Fi F f = 2324N

-vmax
1

5 6

10

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-18

Running Lengths Depending on Usage

Running distance during acceleration:

laccl =

(v1 + v2 )taccl
2

(v1 + v2 )tdecl

Running distance during deceleration: ldecl =

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-19

Mean Axial Force

Determine mean axial load in the positive direction by collecting all individual,
positive axial loads.

Fa ,mean + = 3

F l
l

3
ai + i +

i+

Determine mean axial load in the negative direction by collecting all individual,
negative axial loads.

Fa , mean = 3

F
l

3
ai i

Determine mean axial load:

Fa ,mean =

Fa ,mean + + Fa ,mean
2

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-20

10

Load Profile Based on Utilization

Mean axial force:

Fa ,mean = 3

3
3
Fm3lm + Funi
luni + Faccl
laccl
lb

Fm:
Funi:
Faccl:
lm:
luni:
laccl:
lb:

Machining force
Force at constant velocity (not machining)
Maximum force during acceleration and deceleration
Total travel per cycle during machining
Total travel per cycle at constant velocity
Total travel per cycle during acceleration and deceleration
Length of ball screw

Total travel length:

lb = lm + luni + laccl

Travel length:

lm = qm lb
luni = quni lb
laccl = qaccl lb
ME EN 7960 Precision Machine Design Ball Screw Calculations

4-21

Load Profile Based on Utilization (contd.)

qm + quni + qaccl = 1

Utilization:
qm:
quni:
qaccl:

Percentage per cycle spent machining (typically 0.5 0.9)

Percentage per cycle spent at constant velocity (typically 0.05 0.45)
Percentage per cycle spent during acceleration and deceleration (typically 0.05 0.1)

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-22

11

Dynamic Load Rating Ca and Life

When the rotation life L has been obtained, the life time
can be obtained according to the following formula if the
stroke length and the operation frequency are constant:
Rotation life [rev]
Life time [hr]
mean rotational speed [min-1]

L:
Lh:
nm :

L
Lh =
60nm

(n l )
=
l
i i

nm

ni:
l i:

rotational speed at phase i [min-1]

distance traveled at phase i [m]

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-23

Axial Rigidity

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-24

12

Axial Rigidity
Fixed-free
Fixed-supported

1 1
1
1
1
= +
+ +
k ks k N kB kH

Fixed-fixed

1 1
1
1
1
= +
+
+
k k s k N k B1 + k B 2 k H 1 + k H 2

k:
k s:
kN:
kB:
kH:

Axial rigidity of linear motion system [N/m]

Axial rigidity of screw shaft [N/m]
Axial rigidity of nut [N/m]
Axial rigidity of support bearing [N/m]
Axial rigidity of support housing [N/m]
ME EN 7960 Precision Machine Design Ball Screw Calculations

4-25

Ball Screw Selection Procedure

Axial rigidity of shaft
Fixed-free and fixed-supported:

ks =

AE
L

Fixed-fixed:

AEL
ab
4 AE
k s ,min =
L

ks =

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-26

13

Ball Screw Accuracy

Applicable if used in combination with rotary encoders.

Source: THK Co., Ltd.

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-27

Overall Error
The overall error is the summation of a number of individual errors:

Non-uniformity of threaded shaft.

Resolution/accuracy of rotary encoder.
Axial compliance of ball screw assembly.
Torsional compliance of threaded shaft.

a = S +
a:
s:
l:
Nrot:
Fa:

32Tl l
F
l
+ a + 4b
N rot k axial d tr G 2

overall linear error [m]

ball screw non-linearity [m]
lead [m]
resolution of rotary encoder
[pulses/rev]
thrust force onto system [N]

kaxial:
:
lb:
dtr:
G:

overall linear stiffness [N/m]

applied torque [Nm]
ball screw length [m]
root diameter of shaft [m]
shear modulus [Pa]

ME EN 7960 Precision Machine Design Ball Screw Calculations

4-28

14