CONTENTS

Introduction
Historical review
Principal setup
Spindle analysis
Mechanical design and components
Sensor integration/condition monitoring
Mechatronic concepts
Conclusions
References
INTRODUCTION

Machine tool spindles basically fulfill two tasks:

1. Rotate the tools (drilling, milling and grinding) or work piece (turning) precisely in space.
2. Transmit the required energy to the cutting zone for metal removal.

Obviously spindles have a strong influence on metal removal rates and quality of the
machined parts.

Among all the components of the machine tools, the spindle is the most critical part, since
its dynamic properties directly affect the cutting ability of the whole machine tool.
HISTORICAL REVIEW

Classically, main spindles were driven by belts or gears.

Later simple electrical or hydraulic controllers were developed and the rotational speed
of the spindle could be changed.

The need for increased productivity led to higher speed machining requirements which
led to the development of new bearings, power electronics and inverter systems.

Through the early 1980s high spindle speeds were achievable only by using active
magnetic bearings.

Continuous developments in bearings, lubrication, the rolling element materials and

drive systems (motors and converters) have allowed the construction of direct drive
motor spindles.
PRINCIPAL SETUP
Today, the overwhelming majority of machine tools are equipped with motorized
spindles.

The motorized spindles do not require mechanical transmission elements like

gears and couplings.

The spindles have at least two sets of mainly ball bearing systems.

The bearing system is the component with the greatest influence on the lifetime
of a spindle.

Due to high ratio of power to volume active cooling is often required.

Which is generally implemented through water based cooling.

 Seals at the tool end of the spindle prevent the intrusion of chips and cutting
fluid.

A standardized tool interface such as HSK and SK is placed at the spindles front
end.

A clamping system is used for fast automatic tool changes.

Today, nearly every spindle is equipped with sensors for monitoring

The motor temperature.
2. The position of the clamping system.

Additional sensors for monitoring:

The bearings, the drive and the process stability.
 FIELDS OF APPLICATION AND SPECIFIC DEMANDS

Spindles are developed and manufactured for a wide range of machine tool
applications.
A common goal of maximizing the MRR and part machining accuracy.
SPINDLE ANALYSIS

The aim of modelling and analysis of spindle units is:-

Simulate the performance of the spindle and optimize its dimensions during the
design stage.
To achieve maximum dynamic stiffness and increased material removal rate with
minimal dimensions and power consumption.

The mechanical part of the spindle assembly consists of :-

Hollow spindle shaft mounted to a housing with bearings.

Angular contact ball bearings are most commonly used in high-speed spindles.
Due to their low-friction properties and ability to withstand external loads in both
axial and radial directions.
 The spindle shaft is modelled by beam, brick or pipe elements in finite
element environment.

The bearing stiffness is modelled as a function of ball bearing contact angle,

preload caused by the external load or thermal expansion of the spindle during
operation.

The equation of motion is derived in matrix form :-

By including gyroscopic and centrifugal effects.

And solved to obtain :-

Natural frequencies
Vibration mode shapes
Frequency response function at the tool attached to the spindle.
Flowchart of spindle analysis.