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Developments in Machine Tool Spindle Technology

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 Research and Development in Machine Design
Volume 4 Issue 1

Developments in Machine Tool Spindle Technology

Himanshu Bhatt*1, Himanshu Bist2
1,2
Department of Mechanical Engineering, Delhi Technological University, Shahbad
Daulatpur Village, Rohini, Delhi

*Corresponding Author
E-mail Id:- dbhatt.com@gmail.com

ABSTRACT
Machine tool spindles have a great importance in machine tools. As the machining processes
have developed over the years, there has been a continuous need of development of machine
spindles with them. This paper gives a review of some of the developments and researches that
had taken place in the machine tool spindles such as use of air-assisted bearings, development
of a new cooling strategy for reducing thermal errors and a new concept for Parallel High
Speed Machining (PHSC). The paper also discusses the Hybrid Spindles which are used for
high-performance cuttings and a new ultrasonic spindle which uses fluctuating
electromagnetic force for inducing the ultrasonic vibrations. Along with them, this paper also
reviews a spindle which uses a centrifugal component for automatically adjusting the preload
changes on spindle caused by the centrifugal forces and concept of a spindle which is driven
by water flow and uses a hydrostatic bearing for supporting the spindle.

Keywords:-Machine tool spindle, hybrid spindle, ultrasonic spindle, hydrostatic bearing,

controlling preload

INTRODUCTION property positively affects the machining

The machine tool spindle is one of the
important in mechanical machining
processes. The spindle is a rotating shaft
that holds a cutting tool that cuts the
material, which is clamped and fixed to the
machining tool table in the form of chips.
The machine tool spindle structural
productivity and its surface finish. The
structural properties majorly depend on the
power source like motors, tool holder
system, the design of spindle assembly,
bearing used, and the dimensional
specification of the shaft as shown in
Figure1[1].

Fig.1:-Sectional view of a spindle [2]

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 Research and Development in Machine Design
Historically, the spindles were driven by
belt drives and gear drives. The rotation
speed is only varied by changing either the
driven poles quantity by electrified
switches or the transmission ratio. But later
some hydraulic and electrified controlled
spindle was developed and the rotation
speed changed by ward Leonard motor
control system which is an adjustable
rotating transformer.[3]
Nowadays, manufacturing industries have
become more globalized. The
manufacturers are always looking for the
most efficient and economical ways to
improve the machine tools' productivity by
adopting convenient power source density,
targeting higher speeds, more flexibility,
and multitasking operations. And the only
method to achieve this by continuous
improvement and innovation in the
machine tool spindle technology.
Therefore, research for manufacturing
industries is a very beneficial field of new-
age researchers.
Flexible manufacturing centers capable of
executing a variety of programmed tasks
are modern machine tools. In all machine
tools, spindles are a key component. They
are used to conduct a variety of cutting
operations on for example, items made of
cast metal. To achieve their final shape and
specification, these products involve
finishing through processes such as turning,
cutting, drilling, countersinking, tapping,
reaming, grinding and milling. Significant
fields of use include the automotive and
aerospace sectors.
LITERATURE REVIEW
Greco et al. [4] proposed a spindle design
for micro-machining processes. They
designed a new ultrasonic-assisted air
bearing spindle that can reach higher
rotational speeds at low radial run-outs.
They used an air-turbine in accordance with
the design of a Pelton Wheel for driving the
spindle’s rotor. They used a thrust and a
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Volume 4 Issue 1
pair of journal air bearings for supporting
the rotor and located one journal bearing
close to the tool for minimizing the radial
run-out.
A new cooling strategy has been presented
by [5] for reducing the thermal errors
caused due to the distortion of the spindle
from its reference position because of the
rise in the temperature of various
components of machine tools during high
speed machining. This new strategy has
been referred to as CTM, Cooler Trigger
Model. This operates by dynamically
controlling the frequency and the working
time of the compressor of standard bath
recirculation unit so that the extraction of
heat is in accordance with generation.
Design optimization as per the PSO,
Particle Swarm Optimization, of a spindle-
bearing system was performed by [6] by
optimizing the natural frequencies, static
stiffness and total friction torque. The
design was optimized for two sets of
adjacent bearing positions and preload and
through simulations and experiments;
improved performance of the optimized
design was verified. The optimized spindle
could increase static stiffness by 26% and
the natural frequencies 1 and 2 by 10% and
16% respectively, under the same friction
torque.
Harpaz et al. [7] proposed a new concept of
spindle for Parallel High Speed Machining
(PHSM) processes. This new air-lubricant
based spindle is mounted as an additional
spindle on the machine tool, parallelly to
the main spindle. It can allow speeds upto
90,000rpm and also improves the finishing
and micromachining operations. Early
prototypes when used with high pressure
cooling lubricant for micromachining,
higher performance, good tool life and good
surface quality were achieved.
Vyroubal [8] presented a new method for
analyzing thermal deformation behaviour
of machines due to spindle rotation thermal
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 Research and Development in Machine Design
load, along the direction of the spindle axis.
This uses a specially designed machine
frame which measures the deformation of
machine column, headstock and spindle. A
compensation mechanism is then
developed which is based on a regression
approach, but considers different thermal
dynamic of each machine part to thermal
load. Only temperature measurement with
new measurement places like spindle
cooling and workspace is used for
improving the accuracy of calculation.
The ball-bearing is the pivotal component
of a spindle for supporting the shaft and its
characteristics are closely related to the
preload on the spindle. Ciou and Lee [9]
designed a controlling mechanism for
spindle preload using a single piezoelectric
actuator and wedge-shaped spacer ring.
Fig.2:-Hybrid Spindle[10]
The efficiency of machining is increased by
choosing optimum and efficient processes
such as HPC, and HSC. There are majorly
two difficulties and issues in designing the
traditional spindle for HPC, or HSC. First,
the spindle design of the bearing for
excessive rigid and high-speed results in a
inconsistency; transmitting large cutting
forces with the least deformation of the
bearings have to be in excessively rigid.
Because of centrifugal forces, the high
thermal-mechanical loads are subjected to
the bearing and bearing heat up, resulting in
thermal-mechanical fluctuations. As a
result, the machining spindle bearing
experiences a preload increase caused by
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Volume 4 Issue 1
They tested an experimental full-sized
model and results revealed that an increased
preload causes reduction in vibration
amplitude, which is important for high-
precision spindles used in high speed and
highly precised machine tools.
HYBRID SPINDLE
One of the developing technologies in the
field of manufacturing technology is the
hybrid spindle. Their combination of the
potential spindle motor and the spindle
functionality results in a wide range of
milling spindle [10]. A motor-driven
machining spindle is typically used for
specialised operations such as High-
Performance Cutting (HPC) or High-Speed
Cutting (HSC). Different machining
procedures necessitate different torque and
cutting speed ranges as shown in Figure 2.
the thermal expansion, which leads to loss
of power in spindle bearings. Therefore,
preferably a smaller diameter of the bearing
and low preload are taken into account.
Second, the other limiting factor is the
winding system in the machine tool spindle
motor. The maximum rotational speed is
controlled by the output frequency and
voltage of the source. The maximum torque
depends upon maximum current, and also
the no. of turns in a single phase is
dependent upon the ratio of voltage to
current. High torque and high speed are
controlled by the number of turns in a single
phase. High torque and high speed are
controlled by the number of turns in a single
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 Research and Development in Machine Design
phase. For the same voltage source, a High-
Speed Cutting (HSC) allows less turns in a
single step than a High-Performance
Cutting (HPC). The hybrid spindle offers
the most effective approach for using the
machining process's capabilities to solve
these two problems and challenges [11].
It can be concluded that adapting the
spindle bearing motor characteristics and
the preload is not economical. To get the
benefits of a hybrid spindle within an
industry, an expensive way to adjust and
manipulate the preload of bearing. Also, the
characteristic of a motor has to change
electrically. This technique is beneficial to
allow the switching between the working
modes for HPC and HSC. There are two
approaches to do this. First, to approach the
bearing preload bases on a cost-effective
and thermal mechatronic system. The
element is fully equipped with the strain
Fig.3(a):-Thermo mechanical preload element with b) Control loop for preload force
control[11].
MAGNETIC FORCE INDUCED
ULTRASONIC SPINDLE
Rotary ultrasonic machining is used
throughout the industry for a variety of
operations such as milling, drilling,
threading and many more. It involves the
use of an ultrasonic vibration spindle, at the
end face of which the tool is attached so that
the tool can be ultrasonically vibrated. The
two types of transducers that are generally
used for inducing ultrasonic vibrations to
spindle are made up of piezoceramics and
ferrite. The piezoceramics one involves use
of carbon brushes and slip-rings, where the
occasional poor contact between them leads
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Volume 4 Issue 1
gauges as a force control loop input to
manipulate the preload of bearing subjected
by the preload element. The current preload
forces are detected by the strain gauges.
However, the signals of strain induced by
force are superimposed by signs of thermal-
induced deformations in the preload
element. Now, the temperature change is
caused by the integrated Peltier elements,
spindle motor, and friction as shown in
Figure 3a and 3b. These factors can be
diminishing by connecting the strain gauges
to a Wheatstone bridge. The second
approach, the spindle motors, are designed
by a reconfigurable winding system. A
changeable no. of branches which is
parallel allows the motor properties' change
and enables a transition between HSC, and
HPC by decreasing the number of
turns/phase.
to failure whereas the ferrite ones suffer
high electrical losses due to high thermal
generation in ferrite materials. To
overcome these drawbacks, a new
technique has been developed which makes
use of fluctuating electromagnetic force for
inducing the ultrasonic vibrations.
The new spindle [12] has a cylindrical
body, with 2 driving discs and two flanges.
It is supported by two housings on a base
plate through the flanges and bearings. A
tool can be attached to the front end of the
spindle, and a motor is connected at rear
end for providing rotational motion to the
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 Research and Development in Machine Design
Volume 4 Issue 1

spindle. The spindle’s resonant vibration
mode is 3rd longitudinal vibration (L3
mode), thus making 3 vibration nodes along
the spindle’s length. The two flanges can be
placed at front and end nodes to support the
spindle. The two discs are placed at the
points of maximum amplitude of the L3
mode for the easy induction of ultrasonic
vibrations in the spindle. Four
electromagnets are placed on each of two
discs with some gap for producing
fluctuating magnetic forces. When all
electromagnets are supplied the same AC
voltage at the L3 mode of spindle, spindle
begins to vibrate ultrasonically along its
axis, which then vibrates the tool, because
of the generation and action of
electromagnetic forces on driving discs.
The amplitude of vibration of spindle
depends upon the frequency and amplitude
of AC voltage and the gap between
electromagnets as shown in Figure 4 and 5.

Fig.4:-Schematic for new Ultrasonic spindle [12]

Fig.5:-Constructed Unit [12]

The electromagnets are responsible for the enough magnetic field to produce
fluctuating magnetic forces which vibrations.
ultimately induces vibration in the spindle.
Thus, it becomes essential to use CONTROLLING PRELOAD USING
electromagnets that can produce sufficient CENTRIFUGAL FORCE
magnetic fields. Pure iron steel and Machine tool spindles use rolling bearings
enameled wire is used for core and coil since they provide high stiffness and high
materials because of their high load capacity which is required by spindles
permeability, so that they can produce for high speed and high efficient machining
operations. For spindles using rolling

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bearings, a preload is applied initially
which increases the stiffness of the spindle
and limits vibrations. A greater preload
helps by increasing the stiffness of the
bearing, but it also destroys the oil film
because of high contact stress between the
bearings and the raceways, ultimately
shortening the life of the bearing. When the
spindle rotates at high speed, there is
sufficient increase in the load because of the
centrifugal force and heat generated which
affects the life of bearing. In cases where
lighter preload is applied, the stiffness
characteristics are undermined which are
Fig.6:-Automatic Preload Device utilizing
Centrifugal force [13]
The centrifugal component has 3 parts and
is assembled about the shaft as shown in
Figure 7. Part 1 is in the shape of a hollow
cylinder, and it’s amount of expansion in
radial direction is smaller in comparison
with part 2. Part 2 is a group of various
sections of a cylinder. It doesn’t have any
constraint in radial direction due to which it
has a greater expansion amount as
compared to part 1. Part 3 is compressed
between the 1st and 2nd parts and extends
along the axial direction. When the spindle
rotates, centrifugal force acting on the
rotational components and difference in the
conditions of constraint causes
displacement of part 2 along the axial
direction. Due to this displacement, the
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Research and Development in Machine Design
Volume 4 Issue 1
important for high speed and high efficient
machining.
The new preload device[13] solves this
issue by automatically adjusting the preload
on the spindle using the changes in the
centrifugal force as shown in Figure 6. It
uses a centrifugal element to adjust the
preload automatically as opposed to the
most commonly used hydraulic pressure
method and piezoactuators. Its structure is
made up of centrifugal element, main and
auxiliary bearings, nuts and a constant
pressure preload spring. The preload to be
applied initially is found by the use of
springs and fastening level of nuts.
Fig.7:-Arrangement of centrifugal component
[13]
outer ring of main bearing gets pushed
through the auxiliary bearing and causes
decrement of preload on main bearing.
This displacement of main bearing depends
upon the contact force between part 2 and
auxiliary bearing, auxiliary spring’s
stiffness and characteristics of spring used.
When the contact force increases because
of centrifugal force, preload on the main
bearing decreases. The decrease in the
preload will be high in case of small spring
force.
SPINDLE SUPPORTED BY HIGH
STIFFNESS WATER HYDROSTATIC
BEARING
Page 6
 Research and Development in Machine Design
In ultra-precise machining tools, the
precision spindle plays an essential role in
producing precise parts like lenses. The
accuracy needed for the details reaches
nanometers. Therefore, the high stiffness
bearings are highly required for ultra-
precise machining tools. Commonly, the
accuracy of machining processes depends
on the accuracy of the machining spindle's
rotary motion. The machining spindle of the
ultra-precise machine tools is beared by
radial bearings and hydrostatic thrust,
avoiding mechanical touching of the shaft
and other moving parts. The hydrostatic
bearing notably affects the precision of the
mechanical rotational motion of the
Fig.8:-Schematic diagram for water driven spindle with hydrostatic bearings[14]
The spindle worked for the actual diamond
rotation must be handled by radial bearings
and the hydrostatic thrust. The sliding
bearing supports the spindle shaft for
easiness in the structural point. As we
know, bearing characteristic restrictions is
an essential and influential factor of
stiffness. Therefore, the restrictors of the
spindle are designed to maximize the
bearing rigidity. Besides, the proper
selection of material is necessary. For the
bearing parts of the water, hydrostatic
bearing because of the great lubricative
property of water. However, the moving
parts beared by the hydrostatic bearing
don't directly touching with moving mating
parts. In this case, the pieces were made up
of steel majorly stainless steel. Because of
the deficiency of water's lubricative
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Volume 4 Issue 1
machining tool spindle. And the dependent
performance index of the water hydrostatic
bearing is the bearing rigidity.[14]
The stiffness of bearing stated that the
outward load is divided by the spindle
rotor's associated displacement along the
force direction. Also, the considerable
stiffness of the bearing is subjected to the
spindle's small resultant displacement, and
it's desirable to attain more significant
precise machining. The required
preciseness of machining the generated
parts by the diamond turning processes is
tens of nanometers of value as shown in
Figure 8.
property, the damages take place if the
contact happens. Somebody must also
consider the selections of material for the
hydrostatic bearings for the bearings pads:
forbearing pads, ceramics, gunmetal,
carbon-based resin, and several engineering
plastics.
CONCLUSION
Spindles are an important part for the
machine tools and as the machining
processes have developed, a lot of different
developments have been made to the
spindles also. From the review, we see that
concepts such as using an air-turbine based
on pelton wheel design for driving the
spindle’s rotor, optimization of multiple
objectives as per the PSO (Particle Swarm
Optimization) and analyzing the thermal
Page 7
 Research and Development in Machine Design
deformation by using a specially designed
frame and then developing a compensation
mechanism based on regression approach
have been developed.
Some of the developments has been the
hybrid spindle, which uses a combination of
the potential spindle motor & the spindle
functionality, an ultrasonic spindle which
instead of using piezoceramics and ferrite
uses fluctuating electromagnetic force for
inducing the ultrasonic vibrations and a
spindle which uses a new centrifugal device
for the automatic adjustment of preload as
the higher or lower preload can affect
proper functionality.
There is also a spindle which uses water
flow for driving the spindle, supporting the
spindle through hydrostatic bearing and for
cooling the spindle. From the above
research we can conclude that spindle
technology has continuously evolved, as
]the machine tools and machining processes
have developed and continuous research in
spindles is necessary to keep up with the
other related developments.
REFERENCES
1. Maeda, O., Cao, Y., Altintas, Y.
(2005). Expert spindle design system.
International Journal of Machine
Tools and Manufacture, 45(4–5), 537–
548.
2. De Ciurana, J., Quintana, G., Campa,
F. J. (2009). Machine Tool Spindles.
Machine Tools for High Performance
Machining (pp. 75–127).
3. Abele, E., Altintas, Y., Brecher, C.
(2010). Machine tool spindle units.
CIRP Annals, 59(2), 781–802.
4. Greco, S., Lange, A., Kirsch, B.,
Aurich, J. C. (2019). Simulation-based
design of an ultrasonic-assisted air
bearing spindle for micro machining.
Procedia CIRP, 82, 160–165.
5. Grama, S. N., Mathur, A., & Badhe, A.
N. (2018). A model-based cooling
strategy for motorized spindle to
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Volume 4 Issue 1
reduce thermal errors. International
Journal of Machine Tools and
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6. Tong, V.-C., Hwang, J., Shim, J., Oh,
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10. WEISS SpindleTechnologies gmbh, A
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11. Denkena, B., Bergmann, B., Mücke,
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13. Hwang, Y. K., Lee, C. M. (2009).
Development of automatic variable
preload device for spindle bearing by
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 Research and Development in Machine Design
Volume 4 Issue 1

using centrifugal force. International supported by water hydrostatic bearing

Journal of Machine Tools and for ultra-precision machine tool. Proc.
Manufacture, 49(10), 781–787. of ASPE 2003 Annual Meeting.
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(2003) Water energy drive spindle

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